NO.MEC/GS/Q693/11/40/04, Rev.0 MARCH, 2006

INDIA

FLUID SYSTEM

GENERAL SPECIFICATION

KALINGA NAGAR INDUSTRIAL COMPLEX

(GS-04)

NINL-PHASE-II

MECON LIMITEDRANCHI - 834002

NEELACHAL ISPAT NIGAM LIMITED

DUBURI, ORISSA - 755026

IRON AND STEEL PLANT

FOR

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01. WATER SYSTEM

01.01 PUMP HOUSE

01.01.01 Design criteria for pump house

The layout of the various equipment inside the pump house shall be designed by the

tenderer keeping in view the safety of the personnel and accessibility of equipment.

The Pump house shall be of Civil construction. Equipment layout including design load

data, equipment foundation size, layout of pump house, details of electrics, cable layout

etc shall be furnished by the tenderer.

Structural platform with ladder shall be provided so that the valves can be easily

accessible of operation and maintenance.

The makeup water shall be drawn into the sump through a float and motorized valve.

An isolation valve shall be provided upstream of the float valve.

The sump/suction chamber shall be designed as per the standard of Hydraulic Institute.

Sump model tests shall be conducted, if necessary. The sump/suction chamber shall

have two compartments with provisions to tank to divert the entire flow form the

cooling tower/ settling tank to either of other compartments when one of the

compartments is under repair/maintenance. Cast iron sluice gates shall be provided for

isolation of the compartments.

The pump house shall be provided with proper ventilation, electrics, illumination,

instrumentation, telecommunication, wall clock and hoisting and handling equipment.

All the controls for the recirculation system and cooling tower shall be provided and the

control panel shall depict the working condition of various units.

The electrics of the pump house shall be designed as per the contract specification

given in the relevant chapter.

The capacity of the hoisting and handling equipment shall be selected in such a manner

that it is able to handle the single heaviest load. Cranes/monorails with hoist shall be

provided as indicated in the relevant chapter.

The pump house shall be provided with suitable ventilation facilities. The details of

ventilation shall be as per the write-up of air conditioning and ventilation described in

relevant chapter.

The pump house shall be provided with necessary illumination facilities along with

portable lamps. The details of illuminations have been given in the relevant chapter.

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The pump house shall be provided with a telephone and wall clock.

All the cold water and hot water pumps shall be of horizontal, centrifugal type an shall

have flooded suction. Each pump shall be complete in all respects comprising the

following:

Electric motor may be mounted on the common base plate. The capacity of the prime

mover shall have a pump, margin of 15 % over the BHP absorbed by the pump,

operating at rated parameters.

Flexible coupling and coupling guard.

Foundation bolts, nuts, washers etc.

Mild steel matching flanges bolts, nuts, gasket etc. required at the suction and delivery

flanges along with the pipe reducers.

Each pump shall have independent suction. The delivery line of each pump shall be

connected to the main header. The following flow velocities shall be maintained for the

pump suction and delivery branches.

Diameter Suction side Delivery side

Upto 250 mm 1 to 1.2 m/s 1.5 to 2.0 m/s

Above 250 mm 1.2 to 1.5 m/s 2.0 to 2.5 m/s

Each pump shall be provided with a Butterfly valve on the suction side and a non-return

valve ( Dual plate zip check type) and delivery valve on the delivery side.

Each pump shall be provided with local indication of pressure on suction side and local

indication and signaling of pressure on delivery side

Each header shall be provided with suitable number of valves for isolating and

maintenance purpose.

Each header shall be provided with local indication of pressure and indication, recording

and signaling of flow and temperature, which shall be depicted on the panel of the

control room.

Minimum two drainage pumps (one working and one standby) of vertical non-clog type

centrifugal pumps, of suitable capacity shall be provided to drain out the

leakage/seepage water. The drainage pumps shall operate on water levels in the sump. In

case of drainage pumps and other special type of vertical pumps, the pumps shall

include the electric motor suitable or vertical mounting, motor stool, base plate with

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accessories and fixing bolts, flexible coupling, shaft enclosing pipe column assembly,

bearings, lubrication gaskets and washers pressure gauges, strainer at suction side etc.

the characteristics of the prime mover shall be same as described under the main pumps.

All the valves of diameter 450 mm and above and the valves requiring remote control

operation shall be electrically / Pneumatically operated. Electrically operated valves

shall have provision for manual operation also. All Manual valves of sizes of 125 and

above shall be gear operated.

Dismantling / Rubber Expansion joints near the pumps on both suction and delivery

lines and compensates on the main header shall be provided wherever necessary.

Suitable chemical and biocide dosing facilities shall be provided in the suction chambers

of the pump houses so as to prevent biological growth, ‘scale/ corrosion if any of the

circulating water system. The facilities shall consist of chemical storage tanks of suitable

storage time, dosing pumps (metering type) one working and one reserve. The dosing

system shall be complete in all respects with tanks, pumps, valves, supports agitators

and necessary pipe-work.

The pipe network and valves within the pump house shall be adequately supported so as

to avoid undue stress on the pumps.

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01.02 PIPE WORK

01.02.01 Design Criteria For Pipe Work

The term pipe work referred herein generally cover pipes, fittings (such as bends, tees,

reducers, plugs, nipples, sockets, unions, flanges, crosses etc.)., valves of various types

and functions (such as gate glove butterfly, plug, check diaphragm, electrically

operated, pressure reducing valves, etc.) strainers, filters, hoses, hose couplings hose

clamps, hose nozzles, fire hydrant assemblies, pipe supports, corrosion protection etc.

Pipe work is intended to convey fluids such as different qualities of water and industrial

effluents.

The pipe work shall be designed, manufactures, assembled and tested as per the latest

standards, codes and recommendations of the Indian Standard Institution. SNSI,

ASTM, AWWA, or other equivalent national standards. Pipe work shall be complete in

all respects including all accessories essential for proper installation, operation and

maintenance, even though such items are not specification mentioned in the

specification.

Piping system shall be designed with high degree of reliability so that the systems

perform the duty of fluid handling without any failure under all conditions of plan

operation.

Piping layout must follow good engineering practice. Proper attention shall be paid to

obtain full functional requirement of the piping system with a layout which provides

sufficient clearance for other equipment and operating personnel, convenient

supporting points and neat appearance.

Complete design of piping system shall be subject to approval by the Owner.

The design shall take into account the effect of internal/external pressure, thermal

expansion, self weight of piping, support reactions, surge and water hammer,

earthquake and wind effects at site, corrosion and erosion etc. and any other effects

dictated by good engineering practices.

Piping systems shall not impose undue forces on equipment terminals.

Mild steel / Carbon steel pipelines shall be used in general for water supply facilities

and special quality pipes such as GI/ Cast Iron for drinking and PVC/ MS rubber lined

HDPE Pipes for corrosive fluids.

Pipelines shall be laid over ground on the structural trestle as far as possible.

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As far as possible all the pipelines shall be laid together along the piping corridor. The

piping corridor shall be parallel to and by the side of roads.

All the pipes network shall be provided with manually operated valves for

isolation/controlling purpose. Valves for size 125 mm and above and be gear operated

and valves of size above 450 mm shall be electrically operated.

The pipe network shall be provided with air release valves at high points and drain

valves at the lower points.

Pipeline passing under or through equipment foundations or walls of buildings or any

other inaccessible structure shall be provided with steel encasing pipes for easy

insertion and removal.

All the pressure pipes shall be laid with a nominal slope and the gravity network with

slope of self-cleaning velocities.

Continuous welding MS pipes shall be used for water supply facilities and pipe flanged

at regular intervals and at bends shall be used for slurry and other corrosive fluid

services. For drinking water, screwed and socked GI pipelines shall be used up-to 150-

mm dia.

Except where otherwise specified, all piping shall have butt welded connections with a

minimum of flanged joints for connections to equipment. Branches shall in general, be

formed by welding.

Provision shall be made for branches for cleaning and flushing of pipelines wherever

necessary.

Manholes shall be provided in the gravity pipe networks and the distance between two

manholes shall be 30-50 m depending upon the pipe size.

Compensators shall be provided on the over-ground pipe network to take care of

thermal expansion.

Wherever over-ground pipelines are crossing roads and railway tracks, they shall be

laid on pipe bridges to provide the necessary clearance for the traffic movement. This

should take in to account the various type of vehicles likely to move in the plant.

Valves provided on the over-ground pipe network shall be provided with steel

structural platforms and access ladders.

Walk-able platforms with necessary hand rails shall be provided by the side of

overhead slime troughs and open gravity network, wherever necessary.

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Provision shall be made for support of piping which may be disconnected during

maintenance work. All large pipes and all long pipes shall have at least two supports

each arranged in such a way that any length of piping or valve may be removed without

any additional supports being required.

Pipe supports shall be capable of supporting the pipelines under all conditions of

operation.

All the buried pipelines shall be laid with a nominal slope towards the drain point.

All the buried pipelines shall be laid as far as possible at a depth of about 1000 mm,

below finished ground level (i.e. the top of the pipelines shall be 1.0 m below the

finished ground level).

Isolation /control valves drain valves, air release valve provided on the buried pipe

network shall be housed in suitably sized covered valve pit and the valve pits shall be

of self draining type.

Wherever the buried pipelines are crossing the roads and tracks, they shall be suitable

encased with mild steel pipes or reinforced concrete casing pipes and the different sizes

of the encasing pipes shall be as given below :

Encased pipe

diameter

Encasing pipe Flanged pipe

size (mm)

Diameter for welded pipe

size (mm)

Upto 100 300 250

150 400 300

200 500 400

300 600 400

350 600 500

400 700 600

500 800 700

600 900 800

700 1000 900

800 1100 1000

900 1200 1100

1000 1400 1200

In case a number of pipes are crossing road or track, these pipes shall be laid in a

reinforced concrete culvert having easy access.

Mechanical cleaning and anticorrosive protection of underground MS pipelines shall

conform to IS: 10221 – 1982. The anticorrosive protection of pipelines shall consist of

the following activities in sequence.

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i) Application of one coat of coal tar primer

ii) Application of one coat of coal tar enamel

iii) One wrap of fiber glass tissue

iv) Application of one coat of tar enamel one layer of fiberglass tissue impregnated

in coal.

v) Application of the final coat of a water-resistant white wash.

Alternatively Multilayer coating tape shall consist of:

1) Thermofisible HMHPDE inner wrap of fiber glass and HMHDPE film, coal tar.

2) Final outer wrap of enamel impregnated fiber glass or HMHDPE film.

RCC manholes with removable covers shall be provided for the buried gravity network

and the maximum distance between two manholes shall be 30 to 50 mm depending upon

the pipe size. Manholes of adequate size shall be provided at all pipe junctions.

Where the pipelines cannot be laid overhead on stockades and are crossing roads and

tracks at too many points in a given area, the pipeline may be laid in walk-able tunnels.

Pipelines in tunnels shall be provided with isolating valves, air release valves and drain

valves, which are easily accessible for operation and maintenance. Gland type of

Compensators shall be provided on these pipelines wherever necessary.

Pipelines in tunnels shall be suitable ventilated and illuminated. There shall be minimum

two entries for the tunnel. Each tunnel shall be provided with at-least two vertical

centrifugal, non-clog type drainage pumps (one working and one standby) and these

pumps shall operate automatically based on the liquid levels. Each tunnel shall be

provided with at least a monorail and hoist for erection and maintenance purposes.

Minimum height of the tunnel shall be of 2.0 m and suitable walkway aisles shall be

provided for each tunnel.

Pipelines within the shop buildings shall be laid overhead supported form the building

columns/side walls/cranes girder etc. wherever this is not possible, the pipelines shall be

laid either in tunnel or in pipe trenches (covered with removable slabs of chequered

plates).

Wherever pipelines are crossing form one bay to another parallel bay, they shall be laid

in tunnel or supported form the gable end.

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01.02.02 Pipe Specification

A) Black Pipes DN 15 to DN 50 :

1. End condition : Bevel Ends

2. Class : Schedule 80

3. Material : ASTM.A.53 Gr:B

4. Manufacturing : Seamless

B) Carbon Steel Pipes DN 65 to DN150 as per IS:1239-1990(R.A.-2004) :

1. End condition : Bevel Ends

2. Class : Heavy

3. Material : As per IS: 1387, 1967

4. Manufacturing : ERW process

5. Thickness : As per IS: 1239

C) Pipes above DN 150 as per IS:3589-1991:

1. End condition : Beveled ends for butt welding

2. Material : Carbon steel, Gr. Fe 410

3. Manufacturing : ERW/EFW/SW process

D) Carbon Steel G.I( Galvanised Iron) Pipes DN 15 to DN 150 as per IS: 1239-2004:

1. End condition : Screwed upto DN50,Beveled ends for all the sizes above DN 50.

2. Grade : Heavy

3. Material : Carbon steel, Gr. Fe 410

4. Manufacturing : ERW/EFW/SW process

01.02.03 Dimensional Performance and End Finishes

Tolerance on outside diameter of the pipe and specified thickness shall conform to the

limits laid down in IS:3589-1991. Finish pipe shall not deviate from straightness by

more than 0.2% of the total length.

Pipes to be butt welded shall be supplied with ends beveled to an angle of 30 degrees (+

5 degree – 0 degree).

Pipelines shall be laid over-ground on structural trestle as far as possible.

As far as possible all the pipelines shall be laid together along the piping corridor. The

piping corridor shall be parallel to and by the side of roads.

All the pipes in network shall be provided with manually operated valves for

isolation/controlling purpose. Valves for size 125 mm and above shall be gear operated.

The pipe network shall be provided with air release valves at high points and drain

valves at the lower points.

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01.03. EFFLUENT TREATMENT PLANT (ETP) FOR G.C.P

01.03.01 General

Effluent treatment plant shall essentially comprise, but not be limited to the following

units/facilities:

Sl.

No.

Description Qty

(Nos.)

1 Inlet slurry launder of carbon steel construction with walk-way,

hand-rails and structural support.

1

2 Flash mixer complete with mixer blade, shaft, gearbox, motor,

base plate, supports, etc.

2

3 Manual bar screen 1

4 Sluice gates 2

5 High-rate thickeners complete with raker arm, lifting device, feed

well, approach bridge, drive motor gear box, limit switches,

common base plate, etc

2

6 Under flow slurry pumps and slurry recirculation pumps in Ni-

hard construction complete with drive motor, base plate coupling,

coupling guards, bolts, nuts, gaskets, etc. with provision for

compressed air agitator at bottom

4+4

7 Sludge storage tank with agitator mechanism complete with

paddle, shaft , motor, gear-box, base-plate, platforms, handrails,

etc.

1

8 Flocculent agitator with MSRL tank, drive motor, etc 2

9 Metering pump with drive motor 4

10 Slurry disposal pump in Ni-hard construction complete with drive

motor, coupling, etc.

1

11 Plug valves, ball valves, gate valves, and non-return valves 1 lot

12 Carbon steel slurry pipelines(heavy grade), service water pipelines

(medium grade) and drinking water pipelines (GI, medium grade)

1 lot

13 Weighing machine in chemical house 1

14 Sealing water pumps/ Flushing water pumps As

required

15 Material handling facilities As per

TS

16 Instrumentation as required 1 lot

17 Structural supports, hand railing, etc. as required 1 lot

18 Electrics as per T.S. 1 lot

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01.03.02 Broad design Guide-lines.

• Slurry launder Carbon steel launder complete with walk-way, hand rails and structural support,

shall be provided at the discharge point of Gas Cleaning Plant up-to the ETP. The

cross-section and the slope with available level constraints shall be so designed as

to ensure a self cleaning velocity (min. 1.5m/s) to avoid deposition of the solids at

the launder bottom. The minimum free board shall be 300 mm to avoid spillage of

slurry during the plant operation.

• Flash mixer.

Two units of RCC flash mixers (one for each unit of HR thickener) with structural

ladders, platforms, hand-rails, etc. shall be provided to allow 60 sec. mixing time

with the dosing chemical. The out-flow channel with the walk-ways of removable

chequered plates leading to the thickener shall be provided with gates to

control/cut-off the supply of thickeners. Local type pH measurements shall be

provided before and after the chemical dosing.

• Thickeners

Each thickener shall have the capacity to treat 70% the total effluent from Gas

Cleaning Plant. The thickener shall be of central drive type. The racker arm

mechanism with gear reduction unit shall be provided. In the event of racker arm

getting jammed, audio visual signal shall be available at the sludge pump house

control panel. The racker arm shall be provided with lifting device (electro-

mechanical type) and hydraulically operated rake drive with planetary gear box.

Working position of the thickener shall also be depicted in the pump-house. After

encountering max. Torque limit, the rocker arm shall lift automatically to 300mm

and continue to rotate in the lifted position. At the preset torque level, the rocker

arm drive motor shall trip.

Sludge chamber shall be provided with manually operated valves to connect the

pump suction lines. Portable type local pH meter shall be provided to measure the

pH of the clarified water.

• Miscellaneous Requirement Following facilities shall be provided:

(i) Flocculants preparation & Dosing tanks:

• Two preparation tank s of SS-304 construction with manual feeding

system.

• Two nos. holding cum dosing tank of 24 hrs capacity of MSRL

construction.

• Screw type dosing pumps with SS internal shall be provided (one

working + one stand-by ) for each circuit.

• Each of the solution preparation / holding tank shall be provided with

mechanical agitator with electric drive.

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• The agitator of the solution tanks, sludge tanks, shall be both local and

remote control.

(ii) Pumps : following group of pumps shall be provided

• Under flow recirculating pumps (1 working + 1 stand-by) for each

HRT.

• Slurry transfer pumps from storage tank to vacuum filtration plant-2

(1W+1R)

• Flushing pumps (1W+1R).

• Gland sealing pumps (1W+1R).

(iii) Miscellaneous

• All valves for slurry operation shall be lubricated plug valves.

• The unintentional tripping of the drive motors. Jamming of valves

etc shall be accompanied by visual signal at control panel.

• Thickener overflow channel sizing shall be done on 200%

overloading.

Design Parameters of Slurry for GCP

i) Flow rate : m3/h

ii) Total suspended solids : 3000-5000 ppm

iii) pH : 7.3-801

iv) Temperature : 50-60 deg. Celsius

v) Pressure at discharge point : by gravity at about +10m level.

(battery limit of the Bidder)

vi) Analysis of suspended solids

a) Fe2O3 : 71.42%

b) SiO2 : 5%

c) Al2O3 : 1.4%

d) CaO : 6 %

e) MgO : 3.2%

f) P : 0.016%

g) S : 0.483%

vii) Approx. particle size distribution

< 10 micron : 30%

10 to 40 micron : 35%

40-60 micron : 15%

> 60 micron : 20%

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01.03.03 Performance Guarantee & Penalties

After completion of erection, cold tests and hot trial runs and fulfillment of

performance of individual equipment and system, the integrated system performance

guarantee tests shall be conducted by the Contractor to establish the rated output,

quantity of treated effluent and power consumption of the Effluent Treatment Plant.

The performance guarantee tests shall be completed within a time schedule to be

mutually agreed upon between the Purchaser and the contractor. Details of the

performance tests, test procedures and test schedules for the demonstration of the

performance guarantee shall be submitted to the Purchaser and shall be mutually agreed

upon.

Should the performance values fall below acceptable level, the unit/sub unit/equipment

shall be rejected by the Purchaser and the Contractor shall be liable, at the option of the

Purchaser, either to replace the unit/sub unit/equipment or to pay compensation in

addition to the liquidated damage as per the contractor or as may be agreed upon.

The following, system performance value shall be guaranteed by the Contractor:

• The flow rate at the battery limit of the outlet of the ETP shall be ____m3/h.

• Total suspended solids (TSS) content of the treated effluent from the ETP shall

not exceed 100 ppm. Hardness < 1000 mg/I, Chloride < 3000 mg/I.

• Energy consumed as measured at motor control centre of the ETP shall not

exceed the values quoted during the tender stage.

No negative tolerance shall be permissible on capacity and quality of the treated

effluent from the ETP. Further, no positive tolerance shall be permissible for power

consumption of the plant.

01.03.04 Slurry Transfer Pumps

Slurry transfer pumps shall be provided to pump the settled sludge from the HR

Thickener to sludge storage tank/sludge sump of the sludge dewatering plant. The

number of standby pumps shall not be less than two. The capacity of the pumps shall be

decided by the tenderer depending on the quantity of sludge generated. The sludge

pump shall operate continuously and accordingly sizing of the pipeline shall be done.

Each sludge pump shall be able to pump sludge from Sludge storage tank. Sludge

pumps and sludge pipelines shall be provided with suitable flushing connection from

industrial water pipeline network.

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Sludge pump shall be of horizontal centrifugal, type with single end suction and

tangential discharge nozzle and shall be suitable for either front or back pull out

disassembly. The impeller width and volute areas, dictate by the design capacity shall

be so as to offer no restriction to the passage of solids. Provision shall be made for

ready access to wearing parts or renewal.

01.03.05 Slurry Piping:

Flanged carbon steel pipes shall be used for transportation of slurry. The pipe thickness

shall be chosen taking into consideration the abrasive characteristics of the solids in the

slurry. The thickness shall be as per thickness schedule for sludge pipelines.

The pipe sizing shall be decided based on the critical velocities and the abrasive

characteristics of the solids in the slurry. The velocity shall be such that no solids settle

in the pipelines.

The slurry pipelines shall be laid under a nominal slope. The slurry pipe network shall

be provided with necessary shut off valves, air release valves, compensators etc.

The slurry pipelines shall be laid over ground or in covered channels / tunnels. Slurry

pipelines shall have flanged connection at an interval of 8 meters. All bends shall be of

flanged type connections only.

If the nature of slurry being transported is very abrasive, the pipelines shall be provided

with suitable wear resistant lining and the details for the same shall be furnished.

The slurry pipelines shall be provided with flushing and drainage facilities.

Flushing pipeline size should be more than the line to be flushed. Size of the flushing

pipeline shall be one size higher. (DF>DL).

All fittings should be forged and should have long radius (3Dm), thickness of pipe shall

be one size higher than normal pipe thickness.

Flow meter at under flow discharge pipeline shall be provided .

Provision of emergency unloading of slurry from thickener by road tanker shall be

envisaged.

Sealing water shall be provided at least 1.5kg/cm2 higher than the pump operating

pressure. Separate pumps (1w+1R) shall be provided.

Underflow of each thickener shall be collected at common storage tank (Min. retaining

time-2 hrs.) with agitator and shall be pumped with a higher capacity / high head slurry

pump.

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The diameter of slurry pipe leading to sludge pond shall not be less than 80 mm.

Dedicated shall pump shall be provided of under flow slurry of thickener. (1W+1R)

pumps shall be provided for each system.

Duplicate slurry pipelines shall be provided from the effluent treatment plant to sludge

dewatering plant.

01.04. HOISTING & HANDLING EQUIPMENT:

Adequate number of manually operated hoists/ electrically operated hoist/Elect. Under

slung cranes / EOT cranes shall be provided in the pump house/Slag Granulation plant

for easy maintenance at erection of equipment.

Hoisting and handling equipment shall be provided for lifting individual loads weighing

200 kg an over.

The type of lifting device shall be selected based on amount of load to be lifted, height

of lift and frequency or operation and the layout of the equipment to be lifted. In

general if the load of be lifted is 1000kg or more and /or height of lift is 8m and more,

power operated handling equipment shall be provided.

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01.05. CHEMICAL DOSING SYSTEM FOR RECIRCULATION WATER SYSTEM:

01.05.01 Deposit Control Agents

Tenderer shall indicate the trade name, composition, appearance, odour, pH optimal,

pH after dosage, solubility gravity dosage, feeding dosage, solubility, specific gravity

dosage, feeding procedure at feeding points of the deposit control agent.

01.05.02 Corrosion Inhibitors

Suitable corrosion inhibitors shall be used for the control of corrosion n open re-

circulating cooling water systems. The corrosion inhibitor shall be fed to the re-

circulating water, wherever found necessary, by means of a metering pump. Corrosion

resistant feeding equipment shall be used.

Tenderer shall furnish the trade name, composition, appearance, specific gravity ,pH

recommended dosage, optimal pH after dosage, solubility, freezing point, feeding

procedure and feeding points of the corrosion inhibitor.

01.05.03 Antifoulants

Suitable anti-foulants shall be applied for the prevention and removal of iron oxide and

other metallic oxides in the water re-circulating systems wherever found necessary. The

anti-foulant shall have good dispersing properties.

Tenderer shall furnish the trade name, composition appearance, pH specific gravity,

solubility, freezing point, recommended dosing rate, feeding procedure and feeding

points of the anti-foulants.

01.05.04 Biocides

Suitable biocides shall be provided for the control of bacterial, fungal and algal growth

in the re-circulating cooling water systems. The biocides shall have good solubilising

and dispersing properties to ensure good distribution throughout the system and

efficient penetration of the slime masses, to the encountered. Dosing rate and dosing

points shall be judiciously selected taking the following factors into consideration:

i) The nature and extent of the anticipated microbiological contamination for the

different re-circulating water systems.

ii) The type and volume of systems to be treated.

iii) Quality of the makeup water

iv) The degree of recommended control of microbiological contamination.

v) Retention time in the system.

Tenderer shall furnish the trade name, composition, appearance, odour pH, solubility,

freezing point, recommended dosage and procedure of feeding for the biocide.

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01.06 SPARES & CONSUMBALES

01.06.01 Commissioning Spares

Commissioning spares as required shall be in the scope of supply of the Purchaser

along with the equipment. It shall cover requirement of trial runs and part testing also.

01.06.02 Consumables.

The Contractor shall supply consumables like first/initial fill of lubricants, oils, grease,

chemical, resins etc. as required to complete the plant till commissioning. The scope of

consumables shall include electrodes, shims, packing bolts, nuts, gaskets, rivets,

washers etc.

The Contractor shall also indicate the annual requirement of all consumables.

01.06.03 Operating, Maintenance and Capital Spares

The supply of spare parts as necessary and as recommended the respective

manufacturer for two years of reliable and trouble free operation and maintenance of all

equipment under this package shall be supplied by the Contractor.

01.06.04 Special Erection/Maintenance Tools and Tackles.

The Contractor shall supply a complete and unused set of all the special tools and

tackles including required number of tool boxes as required for erection, maintenance,

overhaul or complete replacement of the equipment and components required for the

plant.

All the tools shall be supplied in separate containers clearly marked with the name of

the equipment for which they are intended.

01.06.05 Completeness

The parameters in respect of the equipments or accessories shall be as per requirement

for operating the main plant and the accessories in an efficient and trouble free way.

Any equipment, fittings, materials or supplies which may not be specifically mentioned

in the specification or drawings but which are necessary for smooth and normal

operation of the plant and equipment under this package shall be provided for an

rendered to by the Tenderer without any extra cost. The plant must be complete in all

respects and shall be in perfect running conditions to comply with the guaranteed

performance.

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01.07. PRELIMINARY ACCEPTANCE

01.07.01 General

Before the start of the system/plant, the following conditions shall be fulfilled.

The plant and equipment shall be subjected to tests to prove satisfactory performance as

individual equipment and also as a system on the whole.

Plant and equipment erected shall conform to the approved process flow

diagram/schemes and drawings.

All machines shall be installed correctly as per manufacture’s instructions and drawings

or as directed at site by Purchaser.

01.07.02 Plant/ System startup.

Equipment/system shall be started under the supervision of equipment supplier’s

engineers, who may make such adjustments to establish guaranteed performance.

Detailed startup procedure shall be agreed upon between Purchaser and the Tenderer

before the tests.

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01.08. DRAWINGS,DOCUMENTS FOR COOLING SYSTEM FROM CONTRACTOR.

01.08.01 Drawings/Documents for approval:

a) A comprehensive write up indicating all the technical features of high

pressure stack cooling recirculation system and BF proper cooling system.

b) Fluid balance diagram with parameters, pipe sizing calculations at Battery

limit.

c) Detailed P& I Diagram.

2. Water hydraulic flow diagram with calculations.

3. Process Instrumentation for chemical dosing diagrams including interlocks.

4. Design calculations for chemical dosing, drainage facilities.

5. Design calculations supporting the selection of all the equipment with number and

specifications giving the material of construction of important member of the

equipment.

6. Pressure drop calculations of piping network.

7. Complete layout drawings within the battery limit showing overall dimensions of

individual units, pipe network, channels/launders, drains, manholes, valve pits,

roads, culverts, walkway bridges, brick paving, protection bunds, sludge ponds,

fencing boundary with gates etc. as required.

8. Dimensional general arrangement drawing with plans and cross sectional views of

all units, buildings facilities, incorporating all equipment pipe-work monorails,

ladders, stair cases, platforms, walkways access doors, etc. complete in all respect

with clearance clearly shown between the equipment and the building walls.

9. Dimensional GA drg. of all the equipments giving bill of materials including

material specifications.

10. Complete layout and profile drawings of all the pipelines, launders, channels etc.

Indicating the flow rate, diameter, elevation, consumption points with rate of draw-

off, location of valves, valve chambers, manholes, supports and supporting

arrangement, encasing pipe etc

11. Performance data and predicted characteristic curves of equipment.

12. List of spares parts for two years operation and maintenance.

19

01.08.02. Drgs/Documents Required for Reference

1. Test certificates for all equipment.

2. Civil engineering assignment drgs. Giving load data, layout of piping and cable

channels for equipment foundation design as well as design of channels.

3. List of initial fill of lubricants, consumables special tools and tackles.

4. Operation and maintenance manuals for plant and equipment.

5. Catalogues/literature of equipment.

6. Reproducible/literature of equipment.

7. As built drgs. Upon installation and commissioning incorporating

revision/modifications, if any done during execution of the contract.

01.08.03. Drgs/documents required for inspection

1. Manufacture’s guarantee test certificate.

2. Material test certificates for major component

3. Predicted performance/characteristic curves of equipment.

4. Assembly drawing of equipment indicting pat list bill of material and material

specification.

20

01.09 PUMPS

01.09.01 General

- All the pumps provided in the pump house shall be horizontal centrifugal type

with flooded suction. Drainage pumps installed in sump pits shall be horizontal,

centrifugal type with priming tank arrangement. In the event of space

constraints. The use of vertical centrifugal, non-clog submersible pumps may be

permitted. As far as practicable, pumps of reputed indigenous makes shall be

preferred. Pump type shall be preferably HSC, ESTD(BPO) type pumps are

acceptable on case to case basis.

- The horizontal pumps shall be mounted on a common base plate with the motor

thorough a flexible coupling without any gear reducer. In case of slurry pumps

use of fluid coupling may be permitted. The motor capacity shall have margin

of 20 % over its BHP absorbed at the pump shaft at the duty point. the pumps

shall be complete with companion flanges, bolts, nuts, foundation bolts, etc.

- The head – Vs – discharge characteristics of the pump shall be continuously

rising form the duty point to the shut off point without any zone of instability.

The required duty range for a pump shall be on the stable portion of its head

capacity curve close to the best efficiency point. The head developed at the best

efficiency point shall be close to the required differential pressure so that

throttling is not required at pump discharge. The power-Vs- discharge

characteristics shall be non-overloading type.

- The pump shall be so selected and installed that the available NPSH is not

lower than the required NPSH even in the most adverse operating conditions.

- The pump shall be of proven make and design having material of construction

which is the best of its kind for the particular application and shall be

manufactured using best engineering practices under strict quality control.

Each pump shall be tested as per the standards stipulated elsewhere in this

document. The test shall include hydrostatic test, static and dynamic balancing

tests, performance tests material tests and motor routine tests.

- The pump shaft and bearing shall be adequately sized to take the unbalanced

forced due to mal-operation. The pump gland shall ensure proper sealing

without excessive tightening of the packing. Proper cooling and flushing

arrangement for the gland shall be provided wherever required.

- All moving parts of the pump shall be adequately guarded to prevent any injury

to operating personnel.

21

- Pumps shall be designed and installed keeping in view the easy accessibility of

its parts for maintenance. All end suction pumps shall be of back-pull-out

design and shall be provided with spacer coupling of adequate length.

- Mechanical seals shall be provided at all pumps envisaged for closed loop

circuit.

- Minimum one standby pump shall be provided for each group of clear water

pumps and drainage pumps. The group of Pumps for scale water or other

abrasive slurries shall be provided with at least two standby units. Special

abrasion resistant material shall be used for these pumps and the design shall

allow easy replacement of parts subject to wear and tear.

- An isolating valve shall be provided on the suction line of each pump and

another isolating valve together with a non-return valve shall be provided at the

delivery line of each pump. Pressure gauges shall be provided at the suction

and delivery flange of each pump.

- The suction pipeline shall be laid at a constant down ward slope from pump

centre line to the suction chamber. Reducers used in the line shall be eccentric

type to keep the top of the suction line straight.

- Each pump shall be provided with adequate safety interlocks including

overload and dry running protection.

- Dismantling joints shall be provided on the delivery side of large size pumps to

facilitate quick maintenance, wherever required.

- All pumps shall be provided with suitable lifting attachments and each pump

installation shall have suitable handling facilities.

- A clear minimum gap of 700 mm shall be maintained between the pump and the

adjacent piping, other equipment or structures for proper movement. In case

the height of the top most part of the pump from the working floor is more than

1.0 m, the minimum clearance shall be increased to 1000 mm.

- The details of pumps should match with the drive motors throughout the

working life of this equipment and to meet operational requirement. High-

speed motors of 3000 rpm shall not be used, as for as practicable. Working

hour meter shall be provided on control panels to monitor conditions and

subsequent ageing / reduced efficiency, etc.

- Vibration readings, etc. of new installation shall be supplied.

22

- Pumps shall be installed and commissioned as per manufacturer’s instructions.

A continuous running for 72 hours shall be required before final acceptance is

given to the pumping installation.

01.09.02. Shop testing of pumps

- All materials, casting and forging shall be of tested quality.

- Pump casing shall be of robust construction and hydrostatically tested at 200%

of the rated pressure of 150 % shut off pressure, whichever is higher. The test

pressure shall be maintained for at least 15 minutes.

- The impellers along with any other unmachined rotating parts shall be tested

for proper balancing in order to avoid undue vibration during operation.

- Performance tests shall be carried on each centrifugal pump. Performance

test shall be made to determine the following.

a) The discharge against a specified head when running at a specified speed

under a specific suction head.

b) The power absorbed by the pump at the shaft (BHP) under the above-

specified conditions.

c) Efficiency of the pump under the above specified conditions.

d) Variation of required NPSH with discharge.

- The pump accessories like bearings, couplings etc. shall be subject to shop

tests as per manufacturer standards.

- The materials of construction of various components of all equipment and

material covered under the scope of his specification shall be certified by the

contractor with regard to their compliance to specifications laid down for

them under relevant clauses of applicable standards and /or the

manufacturing drawings of the contractor duly approved by the purchaser.

Formal material test certificates to the effect shall be issued by the

contractor.

- All test results and certificates including material test certificates shall be

submitted for approval to the purchaser before dispatch of equipment.

23

01.09.03 Material of construction for pumps

A) Horizontal Pumps

Sl. No ITEM MATERIAL

1 IMPELLER Cast Steel , ASTM A 216, WCB

2 CASING CAST IRON (IS 210 FG 260)

3 CASING RING CAST IRON (IS 210 FG 260)

4 SHAFT C-40

5 SHAFT SLEEVE SS – 410

6 GLAND CAST IRON

7 BASE FRAME M.S FABRICATED

8 FLANGES M.S

B) Vertical Pumps:

Sl.No. ITEM MATERIAL

1 IMPELLER CS ASTM A 216, WCB

2 CASING CAST IRON (IS 210 FG 260)

3 CASING RING CAST IRON (IS 210 FG 260)

4 SHAFT C-40

5 SHAFT SLEEVE SS – 410

6 GLAND CAST IRON

7 BASE FRAME M.S FABRICATED

8 COMPANION FLANGES M.S

9 COLUMN PIPE M.S

10 SUCTION STRAINER M.S GALVANISED

C) Material of Construction for SGP Pumps:

Sl.No. ITEM MATERIAL

1 COVER AND FRAME

PLATE

CAST IRON

2 THROAT BRUSH 27% Cr

3 FRAME AND COVER

PLATE LINER

NATURAL RUBBER

4 FRAME PLATE LINER

INSERT

27% Cr

5 VOLUTE LINER 27% Cr

6 IMPELLER 27% Cr

7 SHAFT EN8

8 SHAFT SLEEVE 420c/CA 40

9 STUFFING BOX CAST IRON

10 GLAND 316SS/CF8M

11 BASE CAST IRON (IS 210 FG 260)

12 BEARING HOUSING CAST IRON

13 OTHER BOLTS MILD STEEL(CAD PLATED)

24

01.09.04 Specification for SGP Pumps:

The following pumps will be acceptable for SGP application

� Vertical cantilever Slurry pumps fully assembled with belt drive arrangement

and electric motor.

� Submersible pumps fully assembled with electric motor Trash.

� Pumps with reverse overhead mounted electric motor and V-belt drive, c/w

common base frame for pump motor, and drive assembly. Outboard bearings

and jack shaft arrangement on pump and motor.

� Periodically the bottom of the sump may have 600 to 1000 mm of accumulated

solids (Granulated Slag) build up. The pump selected must be capable of

starting and running under these conditions.

01.09.05 Technical Specification for Diesel Engine Driven Pumpset

01.09.05.01 General

• The diesel engine shall be complete with all standard accessories, battery sets,

battery charger, instruments & control panel, base frame etc.

• The diesel engine shall be compression ignition mechanical direct injection

type, capable of being started by a battery powered electric starter motor, and

shall accept full load within 15 seconds from the receipt of signal to start.

• The diesel engine shall be natural aspirated, super charged or turbo charged and

either air or water-cooled. In case of charge air cooling by means of a belt

driven fan or of a belt driven auxiliary water pump, there shall be multiple belts

such that half the belts should be capable of driving the fan or pump.

• The diesel engine shall be capable of operating continuously (24 hours) on full

load.

• The diesel engine shall be provided with an automatically adjustable governor

to control the engine speed with 10% of its rated speed, under any condition of

load up to the full load rating. The governor shall be set to maintain rated pump

speed at maximum pump load.

• The diesel engine shall be provided within-in-built tachometer to indicate the

speed of the engine in rpm.

• Any manual device fitted to the engine, which could prevent the engine starting,

shall return automatically to the normal position.

• Engines after correction for altitude and ambient temperature shall have bare

engine horsepower rating of 10% in excess of maximum horse power required

to drive the pump at its duty point.

25

• The coupling between the engine and the pump shall allow each unit to be

removed without disturbing the other.

01.09.05.02. Cooling System

• The engine shall be cooled by water from the discharge of the pump (takes off

prior to the pump discharge valve) direct into the engine cylinder jackets via a

pressure reducing device to limit the applied pressure to a safe value as

specified by the engine manufacturer. The outlet connection from this system

shall be terminated at least 150 mm above the engine water outlet pipe and be

directed into an open tundish so that the discharge water is visible.

• The discharge from the engine shall be collected and drained into the nearest

drainage channel.

01.09.05.03. Air Filtration

The air intake system ensure sufficient clean air to the engine. It shall incorporate the

suction air filter, which shall be of oil bath type to supply clean air to the engine.

01.09.05.04 Exhaust System

The hot exhaust gases shall be let-off with suitable system. All the hot parts located at

the working level shall be insulated. The exhaust system shall include:

• Exhaust manifold

• Silencer : The exhaust gas shall be let off through suitable silencer. The total

back pressure shall not exceed the engine manufacturer’s recommendation.

Sufficient length of straight pipe shall be provided after the exhaust silencer to

leave the gases at sufficient height above the engine and outside the engine

room.

• Expansion joint in SS construction to reduce the forces and moment likely to be

transmitted on the engine frame.

01.09.05.05. Fuel System

• Fuel for the engine shall be high-speed diesel oil as per IS : 1460 – 1974.

• Fuel tank and fuel feed pipe shall be provided for the engine.

• The fuel tank shall have the capacity sufficient enough to allow the running of

the engine at full load for 3 hours.

26

• The fuel tank shall be of welded steel construction. The tank shall be mounted

above the engine fuel pump to give gravity feed. The tank shall be fitted with a

level gauge calibrated in liters, filling in and cleaning hand holes, drain cocks,

self supporting from and connection to the engine fuel oil system.

• Valves in the fuel feed pipe between the fuel tank and the engine shall be placed

adjacent to the tank and they shall be located in open position. Plastic tubing

shall not be used.

• A duplex filter to suitable capacity shall be provided for the fuel feed pipe

between the fuel tank and fuel pump.

• Suitable sludge and sediment trap shall be provided for the fuel feeding system.

• The fuel tanks shall be supplied with hand pump for tapping the fuel tank from

oil barrel.

01.09.05.06. Lubricating System

The lubrication system shall be self-contained with the following equipment.

• Sump : To store sufficient lube oil for circulation, suitable sump shall be located

in the engine.

• Pump : Suitable pump for forced lubrication.

• Filter

• Lubricating oil cooler

• Interconnecting piping & tubes in seamless construction.

01.09.05.07. Starting System

The engine shall be capable of manual starting by electric starter motor

Since the pump driven by the diesel engine is not required to run continuously for long

period and the operation will not be frequent, special features shall be built –in the

engine to allow it to start within a very short period, even if it has been remained idle

for a considerable long period.

The engine shall be designed in such away that is shall be started by one operator, if

necessary, without any preliminary heating of the combustion chamber. All

controls/mechanism, which has to be operated in the starting process, will be within

easy reach of the operator.

Automatic cranking shall be effected by a battery driven 24V DC motor having high

starting torque to have adequate ampere-hour capacity to provide the starting power for

the diesel engine. A control panel for starting of the engine through battery to be

provided. Engine START/STOP/TEST buttons shall be provided on control panel. The

27

battery capacity shall be adequate for ten (10) Consecutive starts without recharging

with a cold engine under full compression.

The battery shall be used exclusively for starting the diesel engine and kept fully

charged all the time. Arrangement for both trickle and booster charge shall be provided.

However, when the engine starts or is running, provision shall be kept to ensure that the

charger is automatically disconnected and the battery is charged by the engine dynamo.

At no times it should happen that the battery gets disconnected and is not available to

start the engine.

The charger shall give constant D.C output voltage irrespective of incoming voltage

variation specified. The charger shall be with fully controlled bridge circuit with

diodes.

01.09.05.08. Governing System

The governor shall be fitted with a speed control device, which will control the speed

under all conditions of load.

The governor shall offer the following features:

Engine should be provided with an adjustable governor capable of regulating engine

speed within a range of 10% between shut-off and maximum load condition of the

pump. The governor shall be set to maintain rated pump speed at maximum pump load.

Engine shall be provided with an over-speed shutdown device. It shall be arranged to

shut down the engine at a speed approximately 20% above rated engine speed and for

manual reset, such that the automatic engine controller will continue to show an over-

speed signal, until the device is manually reset to normal operating position.

The governor shall be capable of operating without external power supply.

01.09.05.09. Foundation Frame

Suitable foundation frame with foundation bolts & nuts shall be provided.

01.09.05.10. Instruments

The equipment shall be provided with necessary instruments to check the working of

the engine continuously. The following instruments shall be minimum which will be

provided and the same shall be fixed on a common instrumentation panel mounted

directly on the engine base frame :

• Lubricating oil temperature indicator.

• Lubricating oil pressure indicator.

• Cooling water inlet temperature indicator.

28

• Cooling water outlet temperature indicator.

• Speed-cum-hour meter.

The pressure and temperature gauges shall be of reputed make. The following

protections annunciation also shall be provided.

a. High cooling water outlet temperature

b. Low lubricating oil pressure

Any other instrument, control and protection equipment required for the safe operation

of the engine shall also be provided.

All the pressure gauges, pressure transmitter, pressure switches etc. where viscous fluid

enters inside the instruments shall be provided with diaphragm sealed flanged process

connection with flanged isolation valves.

01.09.05.11. Spares & Special Tools

The bidder shall furnish the list of spares & special tools including the following

mandatory spares, in their scope of supply.

� Two sets of fuel filters, elements & seals

� Two sets of lubricating oil filters, elements & seals

� Two sets of belts (where used)

� Two sets of engine joints, gaskets & hoses

� Two injector nozzles

� Two complete sets of piston rings for each cylinder

� Two inlet valve and two exhaust valves

In addition to the above, the bidder may include any other spare parts and special tools

for maintenance/re-erection of the diesel engine/pump.

29

01.10. DESIGN CRITERIA FOR COOLING TOWERS

01.10.01 General

The cooling towers shall be multi-cell mechanical induced draft type (cross flow/counter

flow type). The design wet bulb temperature of the site is 28 deg. C. the approach of

cold water to design wet bulb temperature shall be fixed based on the requirements.

The cooling towers shall be located near the recirculating water pump house with

necessary clearance from the adjoining structures and communication facilities.

The number of cells in each cooling tower shall be selected in such a manner that when

one of the cells is taken out for maintenance, the remaining cells shall be able to handle

the entire hydraulic and thermal load.

The cooling towers and the accessories shall be designed and constructed in accordance

with the latest applications provisions of Indian or International Standards in general and

the following in particular.

PTC – 23 “ASME Performance Test Code for”atmospheric water cooling equipment”.

Cooling tower institute of USA, Bulletin, ATP - 105 for “Acceptance Test Procedure”

IS: 401 for “Code of practice for preservation of timer”

The cooling towers design shall provide towers suitable for reliable operation in the

climatic conditions prevailing at the site. In addition, the tower design shall include the

following features for reliable operation and fog reduction under varying seasonal

conditions:

- Large air to water volume ratio

- Highly effective draft eliminator design

- High fan cylinder air exit height

- Ability to function well with the fans operating continuously at design airflow

under all operating conditions.

- Capability to adjust to the seasonal variations of circulating water flows.

The towers shall be designed to withstand the wind load and seismic load for the site. The

tower layout shall facilitate location of fan drive motor on that side of the cylinder which

will be upwind most of the time.

30

The cooling towers shall be complete in all respects and shall broadly conform to the

following requirements.

Drift eliminator to limit the drift losses to a maximum of 0.2%.

The cooling tower basin shall be of RCC construction and shall be constructed by the

Contractor. The capacity of the basin shall be designed for approximately 10 minutes

circulating water quantity. Each basin chamber shall be provided with a sludge pit with

isolating valve complete with extended spindle and head stock. Each basin chamber shall

be provided with an overflow of suitable chamber there shall be a cold water outlet sump.

In the connection between basin chamber and outlet sump, there shall be screens with

galvanized angle frame, along with a spare screen for each cell.

Fan decks shall be provided with drainage away from the fan cylinder and shall extend

the full width of the cooling tower covering the water distribution system. The fan

cylinder shall be of FRP construction and shall be of velocity recovery venturi design.

The cooling tower shall be provided with a stairway located at each and of the tower for

access from ground level to the fan deck. The tower will be provided with one or two

longitudinal walkways, with handrails located at the cooling tower basin curb level.

The tower shall be provided with complete water distribution system including piping,

flow control valves and distribution nozzles. Header isolating valves for the tower and

water distribution valves for each cell shall be provided.

The tower shall be equipped with suitable material handling devices of appropriate

capacity for removal and handling of equipment from the fan deck to the ground level.

Each fan assembly shall be provided with vibration limit switches to de-energize the

motor in the event of excessive vibration.

Cooling tower fan shall be multiple axial flow type, specially designed for low noise

level and vibration free operation. The bolts, nuts and other hardware used for fixing the

individual blades to the fan hub shall be selected with min. 15% margin over the power

required at motor output terminal for the duty conditions.

Cooling tower fan shall be driven through right angle heavy duty, industrial type

reduction gear assembly. Reduction gears shall be of oil bath, positive lubricate type,

specially designed for service factor of 2 over fan rated brake power.

The drive shaft shall be designed for high safety factor and the drive shaft assembly shall

be statically and dynamically balanced.

The fill and eliminators shall be built and arranged to permit ease of handling and

removal form the tower. The fill and eliminator members shall be securely retained in

31

position to prevent excessive sagging or falling out of position. All fill supports shall be

of ample size to properly support their respective loads.

Proper illumination facilities for the fan deck and stair cases shall be provided apart form

are illumination. Cooling tower fan controls shall be located in the pump house.

Blow down water from the cooling towers shall be connected to storm water drainage

system. In case, the quality of blow down water is not within the statutory limits for

disposal, the same shall be treated prior to discharging into storm sewer.

01.10.02 Materials of Construction

Sl

No

Component Material recommended

1 Basin R.C.C.

2 Structural members, stairways, cell

partition and fan deck

R.C.C.

3 Fan cylinder FRP

4 Fill PVC / timber (temp>70°C)

5 Support grids Stainless steel wire mesh

6 Drift eliminator AC sheet

7 Fan blades FRP/Aluminum Alloy

8 Spray nozzles polypropylene

9 Fan hub MS Galvanised with GRP

cover

10 Drive shaft SS- 304

11 Fasteners and hard wares SS (AISI 304)

12 Base frame for motor MS Galvanised

01.10.03 Drawings & Documents

i) Drawings & Documents to be furnished along with the offer:

• G.A drawing for cooling tower incorporating principal dimensions, battery

limits, basin details indicating overflow and de-sludging arrangement, positions

of sluice gates and screens in outlet channel and material handling facilities at

fan deck level.

• List of motors and other field devices.

32

• List of local control boxes and push button stations indicating the devices

mounted and their specifications.

• A brief write up giving description of control and annunciation schemes and

safety interlocks.

• The list of list of spares for two years normal operation and the list of special

tools and tackles required for erection, testing and commissioning and

subsequent maintenance along with itemwise price..

ii) Drawings & Documents to be furnished after placement of order:

A) For Approval

i) QAP of various equipment

ii) G.A and schematic view of cooling tower

iii) G.A of fan deck slab

iv) C.S and longitudinal section drawing of cooling tower

v) G.A of fan cylinder

vi) Schedule of complete electrical equipment/ devices with specifications

vii) Fan motor data sheet and G.A of motor

viii) Layout drawing showing location of all electrical equipment / field devices.

ix) Illumination, cable and cable supporting structures layout plan and sections

drawing.

x) Earthing layout drawing with bill of materials.

xi) Cable schedule indicating cable number, point of origin, point of termination,

type, size and length of power and control cable.

xii) Terminal wiring and external cable connection diagrams.

xiii) Detailed design calculations for civil works of cooling tower and civil

construction drawings.

B) For Information (Mechanical)

i) Distribution piping general arrangement

ii) Hot water distribution nozzle and details

iii) Lube oil equipment installation

iv) G.A and C.S drawing of sluice valve ( with material of construction of various

components)

v) G.A of drive shaft assembly ( with material of construction of various

components)

vi) G.A of gear reducer ( with material of construction of various components)

vii) G.A of fan hub blade assembly ( with material of construction of various

components)

33

C) For Information (Electrical)

i) G.A of vibration limit switch

ii) G.A of local push button station

iii) Lighting protection and earthing scheme for cooling tower

iv) Cable schedule and installation details

v) Lighting arrangement

vi) Fan motor characteristic curves

vii) Instruction manual and drawings on erection, operation and maintenance.

viii) Test certificates and catalogues for each equipment

D) For Reference

i) Technical particulars, catalogues, literatures etc.

ii) Shop performance test report on motor, fan, gear box, drive shaft and other

components as per QAP

iii) Final test report and inspection reports.

iv) Operation and maintenance manuals

v) Final test certificates

vi) As-built drawings

vii) Soft copy and reproducible of all final drawings

E) At the time of at the time of delivery of equipment

i) Internal wiring diagram.

ii) Termination and external connection diagrams..

iii) Detailed erection schedule and manuals, assembly drawings, erection sequence,

special precautions to be followed during assembly / erection.

iv) Instruction manuals for testing and commissioning.

v) Maintenance and safety manuals.

vi) GA drg. of the equipment.

34

01.11. VALVES:

Flow control /isolating valves, drain valves, air release valves and Compensators,

wherever necessary, shall be provided for the complete in-shop pipe network.

All valves shall be suitable for service conditions i.e. quality of fluid, flow temperature

and pressure under which they are required to operate.

Valves shall be provided on pipe network for isolation of pipe section and equipment,

control of pressure and flow, venting, draining etc. They shall be suitable located

considering ease of operation and maintenance.

All valves shall be provided with hand wheel and position indictor. The face of each

hand wheel shall be clearly marked with words “Open” and “Shut” with arrows

adjacent to indicate the direction of rotation.

Valves shall be provided with suitable extension spindle and head stock assembly

wherever required. In case gears or bevel system are used , these shall be of cast steel or

suitable grade cast iron with machine cut teeth.

Non-return valves shall be Dual Plate zip check type and shall have a permanent

“Arrow” inscription on its body to indicate direction of flow.

Larger size valves shall be provided with by pass and drain arrangement.

Float operated valve shall be preferably be right angled pattern complete with ball float,

level and other accessories.

Butterfly valves shall be of quotable flanged, tight shut of design with angular travel of

90 deg. from open to shut off position.

35

01.11.02 Specification for Valves

01.11.02.01 Specification for Globe Valve

1 Type Globe valve for water supply pipelines

2 Body & Bonnet GM to IS : 318-1981,(RA'91)Gr LTB – 2, C.I.

3 Wedge GM to IS : 318-1981(RA'91) Gr LTB – 2, C.I.

4 Stem Stainless steel

5 Back seat GM to IS : 318-1981(RA'91) Gr LTB-2

6 Seating surface & rings GM to IS : 318-1981(RA'91) Gr LTB-2

7 Hand wheel Cast Iron to IS:210-1993 Gr. FG-200

8 Gland, Gland plate disc

spindle nut

Non ferrous alloy

9 Gland Packing Asbestos IS:2712-1979

10 Pressure rating PN = 1.6 N/mm2

11 Manufacturing standard IS:778-1984 (RA 1990)/IS:781-1984

12 Max. operating temp 50 deg C

13 Operation Manually operated hand wheel with open and

close direction indication.

14 End connection Screwed upto 40 mm except otherwise

mentioned. Flanged ends for 50 mm & above,

IS:6392-1971 (RA-1988), table 17

15 Hydro static testing Shell test = 15 kg/cm2

Seat test = 10 kg/cm2

Back seat test = 10 kg/cm2

16 Special features required 1- Arrow indicating flow direction

2-Embossed name plate giving details of tag

no.,type & size

17 Service Water

36

01.11.02.02 SPECIFICATION FOR BUTTERFLY VALVES (CAST STEEL)

Manual Operation / Pneumatic Operation/Motor Operated

1 Type Wafer type C.S. Butterfly valve for water

supply pipe lines.

2 Body & Cover ASTM A 216 Gr WCB

3 Disc A 351 SS 304(CF8)

4 Seat, Body/Disc EPDM

5 Pin Stainless Steel, AISI-410

6 Spindle AISI 410

7 Bolting, internal -do- (HT)

8 Bolting, external Carbon Steel, (HT)

9 End connections Wafer type/(Flanged)

Wafer Type- upto DN500

Fabricated, Cast

Body- Beyond DN600

Flanged/ Lugged type

10 Pressure rating PN = 1.6 N/mm2

11 Manufacturing Standard IS-13095,1991/AWWA:C-504/ BS:5155/

IPSS-1-06-012 / API 609

12 Hydro static testing Body:24 kg/cm2

Seat:16 kg/cm2

13 Test certificates Required for material/hydro test

14 Service Water

15 Max. operating temp 100 Deg 0C

16 Type of operation Upto DN125- Lever operated

Beyond DN125- Gear operated

17 Operation Manual / Pneumatic(As and where

specifically mentioned)

Remarks- All valves above DN600 shall be supplied with SS 304 gaskets with

CAF fillers

37

01.11.02.03 Specification for Pneumatic Actuator:

a) Pneumatic Actuators shall be of double acting type for on/off operation and shall

be directly mounted on the valve. Single acting type shall be considered for

fail/safe operation

b) Each pneumatic actuator shall be supplied with

• Single solenoid common for both open &close operation.

• Valve position indicator- Mechanical type.

• Facility for emergency manual operation.

• SS tubing of 3.00 m length along with isolation valve and suitable end

connections for connecting it to ½” MS pipe by welding complete with

required pneumatic tube fittings for connection to dump valve and ½” MS

Pipe.

• Open and close position, proximity switch, 2-wire, universal type

(AC/DC),PLF,IFM make, wired up-to a junction box.

c) All the above accessories shall be mounted on / connected to the valve.

• Actuator shall be capable of operating the valve when the air pressure is 6

Kg/cm2 and shall be able to operate the valve even when the air pressure

drops to 4.5 Kg/cm2.

• Each actuator shall be supplied complete with two or one way solenoid

valves of ¼” pipe size. Material of construction for body shall be Brass.

• Solenoids for all solenoid operated valves shall be suitable for 20 to 240V

AC/DC power (Universal type).

• The enclosure class of solenoids shall be IP65.

• For termination of cable to the solenoid, proximity switches junction box

shall be provided by supplier. Terminals shall be suitable for terminating 2.5

sq. mm copper conductors. 20% spare terminals shall be provided in the

junction box.

• Apart from other tests, performance test for pneumatically operated valves

with respective actuators mounted in position to show valves opening and

closing and observation of leakage shall be conducted.

38

01.11.02.04 Specification for CI/Bronze Plug Valves.

1 Type DN 65 and above: C.I. Two way, lubricated type,

tapered plug : Sizes up-to DN50: Bronze, T port 3

way lubricated type tapered plug

2 Body, Cover &

Gland

CI as per IS:210-1993 FG 220

3 Plug CI as per IS:210-1993 FG 220/

Bronze as per IS:318 LTB-2

4 Fasteners Black Hexagonal bolt with nut as per IS:1364 Part 1

& 3,1992, class 4.6/4

5 Gland Packing Rubberized Asbestos

6 Gaskets CAF

7 End connection Screwed end up-to DN50, NPT/ Flanged end for

DN65 & above as per IS: 6392-1971 (RA'88) with

matching flanges, table-17.

8 Pressure rating PN = 1.6 N/mm2

9 Manufacturing

Standard

BS 5353/API 599

10 Hydro static testing Body:24 kg/cm2

Seat:16 kg/cm2

11 Test certificates Required for material/hydro test

12 Service Cooling water for Blast furnace stove and stove

valves

13 Max. operating

temp

50 deg C

14 Gear arrangement Worm gear of C.S./forged steel

Note: 1. Type of threading for screwed end will be as per IS:554-1999.

2. Plug valve of size DN200 shall be provided with worm gear

arrangement.

01.11.02.05 Specification for Ball Valve / Full Bore / 2 Way / 3 Way

1 Type three piece, Reduced bore, floating ball, PTFE

seated

2 Body, Cover & Gland CS as per ASTM A216 WCB

3 Ball SS , ASTM A 351, Gr. CF 8M

4 Stem AISI 316

5 Fasteners HT, SS 304 only

6 Gland Packing 35% Carbon Filled PTFE/ Graphite

39

7 End connection Socket welded / Flanged ( Refer Detailed Valve

List)

8 Pressure rating PN = 1.6 N/mm2

9 Manufacturing

Standard

BS 5353/API 599

10 Test certificates Required for material/hydro test

11 Service For instrument fitting, air vent and for regulation

purposes.

12 Max. operating temp 100 Deg 0C

13) Remarks- Socket weld connection with nipple pipe of 100mm welded on all

openings

01.11.02.06 Specification for Air Release Valve

Air release valves shall be cast iron, single large orifice type, with flanged ends. Air

release valve shall conform to IS: 14845-2000.

1 Type Air release valves shall be cast iron, single large

orifice type, with flanged ends. Air release valve shall

conform to IS: 14845-2000.

2 Body CIFG 200 as per IS:210

3 Body seat ring Gun metal IS:318 LTB-2

3 Vulcanite ball Vulcanite Ebonite

4 Disc Gun metal IS:318 LTB-2

5 Stem 13% Cr SS IS:1570

6 Disc nut Gun metal IS:318 LTB-2

7 Bolts/studs, nuts Carbon steel IS:1367

8 Gland CI FG 200 as per IS:210

9 Gland packing Graphited asbestos

10 Air release nipple Gun metal IS:318 LTB-2

11 Gasket Compressed asbestos Fiber 3 mm thick

12 Rubber ball Vulcanite Ebonite

13 End connection Screwed up-to DN40 and flanged for DN50

14 Pressure rating PN 1.6 N/mm2

15 Test pressure Body : 24 kg/cm2

Seat : 16 kg/cm2

Test duration : 30 minutes

40

01.11.02.07 Specification for Companion Flanges

1 Type Raised face plate flanges, Slip-on, welded, plate

fabricated, machined finish.

2 Dimensional

Standard

As per IS-6392-1971(RA'88), PN=1.6 /1.0 N/mm2 as

per valve rating, Table-17/11, drilled off centre, RF.

3 Material C.S as per IS-2062 -1992 GR.A.

Note: Valve flanges and matching flanges shall be drilled as per IS:6392-1971

(RA'1988), table 17 for PN 1.6.

01.11.02.08 Specification of Actuator for Motorised Valve for Various Locations.

1 MAKE ROTORK/AUMA/LIMITORQUE

2 OUTPUTMOTION ROTARY

3 OPERATION TIME 90 SEC (MAX)

4 SERVICE CONDITION INLET PR.-8.5 Kg/cm2 (MAX)

INLET TEMP.-40 deg.C max.

FLUID – WATER

5 ACTUATOR SHALL BE SUPPLIED COMPLETE WITH THE

FOLLOWING

A HANDWHEEL FOR MANUAL OPERATION

B POSITION INDICATOR

C OPEN/CLOSE LIMIT SWITCHES

D TORQUE LIMIT SWITCHES

E EACH LIMIT SWITCH SHALL HAVE 2 NO / 2 NC CONTACT

SWITCH FOR 10 AMP. AT 240 V

F MOTOR TERMINALS AND LIMIT SWITCH CONTACTS SHALL BE

WIRED UPTO A TERMINAL BOX TO BE MOUNTED ON THE

VALVE ACTUATOR

41

01.11.02.09 Motor Specifications.

1 Make & Type ABB/NGEF/BHARAT BIJLEE/KEC & 3 PHASE,4

WIRE, SQUIRREL CAGE, INDUCTION MOTOR

2 Supply Conditions 415 V AC + 10%, 50 C/S + 3% -6%

3 Control Voltage 240 V

4 Protection IP-65

5 Enclosure TEFC

6 Duty Condition S2, 30 MINUTES

7 Class of Insulation `F' Temperature rise limited to class-B

8 No. of Starts/hr

Allowed

60

9 Design

Performance

As per IS:325-1996

10 Breakdown Torque Minimum 2.5 TFL or higher

01.11.02.10 SPECIFICATION FOR CAST STEEL DUAL PLATE ZIP CHECK VALVE

1 Type Dual Plate Zip Check Valve

2 Body ASTM A 216 Grade WCB

3 Plate ASTM A 351 Gr. CF8 M (SS 316)

4 Stop Pin AISI SS 410

5 Hinge pin AISI SS 410

6 Spring INCONNEL

7 Retainer CF8M (SS 316)

8 Body Bearing AISI SS 316

9 Plate Bearing AISI SS 316

10 Spring Bearing AISI SS 316

11 Eye Bolt Carbon Steel

12 Body Seal EPDM

13 Plate Seal Integral

14 Body Test Pressure 450 psi (g)

15 Seat Test Pressure 320 psi (g) (Max.) / 285 psi (g) (Mini)

16 Design Standard API 594

17 Dimensions As per API 594

18 Testing As per API 598

19 Special features

required

1. Arrow indicating the flow direction.

2.Embossed name plate giving details of tag No.

size, etc.

20 End Connections Wafer/ Flanged as per Valve list

42

01.12 PLATE HEAT EXCHANGERS :

01.12.01 Equipment Specification

A) The heat exchanger unit shall consist of gasketed plates supported in frame

capable of being opened and closed. The frame provides structural support as well

as pressure containment for the gasketed plates and consists of frame plate,

pressure plate, guide bar & carrying bars, closing studs/nuts and carrying bar

supporting columns.

B) The frame shall be designed to permit future installation of 30% additional plates.

C) Each plate heat exchanger shall be designed for full pressure in each stream

having no pressure on other stream.

D) While designing heat exchange area and number of plates, cleanliness factor on

account of fouling shall be considered as 20%.

E) Carbon steel components in contact with fluid system shall have a corrosion

allowance of min 3mm. All the threaded hardware items like studs and nuts shall

be zinc coated.

F) Minimum thickness of stainless steel plate shall be 0.5 mm.

G) Frame plate in the primary stationary end of the plate heat exchanger. All nozzles

shall be located on frame plate.

I) Inspection openings shall be provided on the pressure plates. These openings shall

be blanked by providing blind flanges. Ball valves shall be provided on the

bottom blind flanges for drain purposes. Handles are to be provided on all the

blind flanges.

J) All nozzles on the frame plate and inspection openings on pressure plate shall be

provided with stainless steel sheet lining conforming to AISI 316.

K) Pressure plate shall be supported in a roller bearing hanger from the carrying bar.

Pressure plate shall move along the carrying bar and shall be guided by the guide

bar.

L) The carrying bar shall be welded to the frame plate and carrying bar support

column. A stainless steel tee section shall be welded to the carrying bar to provide

mounting member for the plates of the plate pack. A smooth surface shall be

provided for roller bearing carrying grove for the whole length of the carrying bar.

Carrying bar shall be designed to support 1.5 times the weight of the flooded

exchanger along with pressure plate, tie rods, nuts and nozzles.

43

M) Guide bar shall be welded to the frame plate and carrying bar supporting column.

It shall be sheathed in stainless steel on the 3 surfaces coming in contact with the

plates and is a guide bar only for the plates.

N) Minimum diameter of tie rod shall be 19 mm.

O) Carbon steel boiler quality plates shall be as per SA 515/516 Grade 60.

P) Plates having thickness of 16 to 50 mm shall be examined ultrasonically as per

ASTM A 435.

Q) The heat exchangers shall be designed, manufactured and tested as per ASME

code Section VIII, Div. 1 and shall be suitable for the duty conditions and

capacities as indicated in the Annexure-I .

R) The plate heat exchangers along with their auxiliary equipment shall be suitable

for the required duty conditions and shall be designed and constructed for

continuous duty.

S) The equipment and auxiliaries shall be designed for quick and economical

maintenance. The equipment shall be easily dismantled without disturbing the

inlet and outlet pipe connections.

T) Stainless steel name plate shall be furnished and securely attached by stainless

steel pins at an easily accessible point on each plate heat exchanger. The plate

shall be stamped with the following minimum information:-

• Purchaser's item no. or tag in 15 mm high letters.

• Serial number of plates heat exchanger

• Capacity in cubic metres per hour both for primary & secondary sides.

• Temperature ranges for primary & secondary liquids.

• Pressure drop in Primary & Secondary sides

• Design code.

44

01.12.02 Inspection & Testing

a) The tests to be conducted at shop for various sub-assemblies/assemblies of

equipment shall include, but not limited to the following:

• Material test

• Testing during manufacture/fabrication like dye penetration tests on

randomly selected plates, high intensity light check for plates

• Dimensional checking

• Hydrostatic tests

• Ultrasonic test for the plates used for frame and pressure plates.

b) All the plate heat exchangers shall be subject to stage inspection by the

successful tenderer's own inspecting authority. However, Purchaser's Inspector

may visit the works from time to time who shall have free access to all the

places of the manufacturing premises where any part/parts are under

manufacturer.

c) The successful tenderer's inspecting authority shall keep a close surveillance in

respect of the quality of job for the design dimensions, tolerances, surface finish

etc.

d) Before giving call for final inspection, all the documents shall be furnished to

the Purchaser. The record of manufacturing details, inspection and tests carried

out by the successful tenderer shall be made available to the final Inspecting

Authority. However, approval and final inspection at the manufacturing works

shall not relieve the successful tenderer of responsibility of replacing at his cost

any defective part/material which may be detected by the purchaser during

erection and commissioning or guarantee period.

e) Hydrostatic test shall be carried out at 1.5 times the design pressure maintaining

test pressure for a minimum of 60 minutes. Testing shall be done by

pressurising each side separately.

f) The final tests shall be conducted in the presence of the Purchaser's

representative. Test certificates for different tests shall be made available to the

Purchaser. Material test certificates for bought out items shall be obtained from

original manufacturer/reputed test house. For all bought out items, test

certificates as relevant to the items shall be furnished by the successful tenderer

before the equipment is offered for final inspection.

45

f) Wherever required, all tests shall be done as per relevant Indian Standards. In

the absence of the Indian Standard, the equivalent internationally reputed

standards shall be followed.

01.12.03 Painting

a) Surface of the heat exchanger frame work shall be cleaned to near white metal

conforming to Sa 2 1/2 of Swedish Std. SIS 055900 or German Std DIN 55928

(Part-4)

b) After surface preparation, the plate heat exchanger shall be painted as per the

manufacturer’s standard.

01.12.04 Acceptance Tests

Acceptance tests shall be carried out by the successful tenderer after commissioning.

These tests shall be performed according to code of practice of HEI of USA or other

mutually agreed procedure in the presence of Purchaser's representative. All

instruments required for the test shall be arranged by the successful tenderer. In Case

during the tests the heat exchanger performance falls short of guarantee figures, the

successful tenderer shall bear all expenses of improving the performance of the heat

exchanger and shall carry out another acceptance test at no extra cost. In case the

performance is again unsatisfactory, the successful tenderer shall be liable to replace

the subject equipment by new and better equipment at no extra cost without affecting

the overall schedule of the commissioning of the Main Plant.

01.12.05 Guarantee

a) All equipment shall be guaranteed for good workmanship, no material defect

and the design parameters till a period of 12 months from the date of successful

commissioning or 18 months from the date of despatch whichever is later.

b) The successful tenderer shall stand guarantee that the heat exchanger shall cool

the required quantity of primary water with the specified quantity of secondary

water to the temperatures stipulated in Annexure A of this technical schedule.

The successful tenderer shall also guarantee the agreed pressure drops across the

primary & secondary sides of heat exchanger. In addition, all items of the heat

exchanger are to be guaranteed in respect of material and workmanship. Any

defects found during warranty period shall be rectified to the complete

satisfaction of the purchaser at the successful tenderer's cost.

01.12.06 Penalty

a) No negative tolerance on the "Overall heat transfer coefficient" of the plate heat

exchangers shall be permitted.

46

b) For every 1% shortfall in the overall heat transfer coefficient, 1% contract value

shall be levied as penalty. This shall be applicable for the overall heat transfer

coefficient up to 95% of the guaranteed value.

c) For overall heat transfer projection less than 95% of the guaranteed value, the

heat exchangers shall be rejected.

d) No positive tolerances on the pressure drop in the heat exchangers shall be

permitted.

e) For every 1% increase in the pressure drop, penalty at the rate of 1% contract

value shall be levied. This shall be applicable for the pressure drop upto 5%

above the guaranteed value.

f) For pressure drop of more than 5% of the guaranteed value heat exchangers

shall be rejected.

g) Guaranteed overall heat transfer coefficients offered by the successful tenderer

shall hold good if the variation in the flow rates is within + 2O% of the flow

rates.

01.12.07 Information to be Furnished with Offer

The Tenderer shall furnish the following documents along with the offer :

• Technical particulars of the plate heat exchanger.

• Preliminary GA drawings of the plate heat exchanger’s alongwith auxiliaries

indicating the overall dimensions.

• Predicted performance curves.

• Catalogues for the plate heat exchangers duly identifying the model.

• List of special tools, tackles and accessories required for assembly, erection,

testing, start-up and commissioning.

• List of minimum commissioning spares that will necessarily be supplied along

with the equipment.

• Testing & acceptance procedure as proposed by the tenderer.

47

01.13. ONLINE AUTOMATIC FILTER

01.13.01 Equipment Specification

01.13.01.01 Mechanism

The online filter shall be of cylindrical body with wedge wire slot tube element housed

in it. For automatic filter, area will be in the ratio of 1:3 where-as for strainer it will be

1:6. The filter should start the self cleaning process when the pressure differential

across the screen reaches a preset value or predetermined lapse of time. Cleaning of the

filter elements is to be carried out by the suction scanner with its spiral rotational

movement.

The filter control shall be carried out by purchaser’s PLC and MCC system. However,

tenderer shall furnish functional description / Control write-up, PLC Input/Output list to

the purchaser.

Flush drain valve and vent shall be provided for each unit of the main filter. The design

of the filter shall be suitable for easy maintenance and replacement of the parts and

inspection.

Each strainer shall be provided with basket opening area (six times of pipe cross section

area or bigger) to ensure high flow volumes at low pressure and a long service life.

Provision shall be made for collection of drainage water from the strainers and shall be

suitably connected to the plant area drainage system.

Along with the offer the Tenderer shall furnish details of the basket filter such as make,

general arrangement and cross sectional drawings, operating parameters, materials of

construction of various components supported by manufacturer's literature and

catalogues.

Valves to be supplied as part of the filters shall conform to the following standards.

Pressure rating of all valves shall be 16kg/cm2.

01.13.01.02 Valve Actuator

All motors shall be suitable for 415V, 3-Phase power supply. Actuators shall be

provided with travel Limit switches and Torque switches. These switches shall have

IP-55 degree of protection. It shall have 2 NO + 2 NC contacts rated for 10 amps AC

a) Electrically operated built-in change over valves shall be complete with electric

motors, necessary gear drive, position limit switches, torque switches and terminal

box.

48

b) Motor shall be squirrel cage induction motor with DOL starter at 415+/- 10% 50Hz

+/- 5% having the following:-

i) Class `F' insulation, temperature rise limited to Class `B'.

ii) TEFC enclosure with degree of protection IP55

c) Arrangement shall be provided on the valve for disconnecting power supply, which

shall operate when valve is opened manually.

d) All end position limit switches and torque switches for open & close position shall

be dust and water proof.

e) All the limit switch contacts shall be wired in a terminal box (part of actuator)

suitable for termination of 14X1.5 mm2 control cable.

01.13.01.03 Shop Testing

Testing and inspection of equipment and materials shall be carried out at the works of

the Contractor or his sub-Contractor during manufacturing and on final product to

ensure conformity of the same with acceptable criteria of Technical Specifications,

approved drawings, authenticated manufacturing drawings and reference

Indian/International standards.

The Contractor shall furnish Quality Assurance Plan (QAP) for each equipment and

material for Employer’s/Consultant’s approval at least two months prior to start of

manufacturing.

Tests to be conducted at the shop for various assemblies/sub-assemblies of

equipment shall include, but not be limited to the following:

• Material test.

• Tests during manufacture/fabrication.

• Dimensional checking.

• Hydraulic test at the shop.

• Performance test.

• Any other test as required

For each of the items being manufactured/supplied, the following test certificates and

documents, as applicable, in requisite copies including original shall be submitted to the

Inspection Agency. All test certificates shall be endorsed by the manufacturer and the

Contractor with linkage to the project, purchase order and acceptance criteria.

• Raw materials identification and physical and chemical test certificates for all

materials used in manufacture of the equipment/

• Welding procedures and welder’s qualification test Certificates,

49

• Static/dynamic balancing certificate for rotating Components/ machines.

• Pressure test certificates.

• Performance tests certificates for all characteristics.

Inspection at manufacturers’ works shall not relieve the Contractor of responsibility for

replacing at his own cost any defective part/material and repairing equipment for

defective workmanship that may be discovered at site at a later date.

01.13.01.04 Shop Painting

The complete paint system for any item shall include

• Surface preparation

• Application of primer coats, intermediate coats and finish coats of specified

paints of Approved quality.

01.13.01.05 Surface Preparation

All surfaces shall be cleaned of loose substances and foreign materials, such as dirt,

rust, scale, oil, grease, welding flux, etc. in order that the prime coat is rigidly anchored

to the virgin metal surface. The surface preparation shall be as per Swedish Standard

SIS 055900 or German Standard DIN 55928 (Part 4) or BS 4232 or IS 1477 Part I).

Procedures for surface preparation shall cover solvent cleaning, hand tool cleaning,

power tool cleaning and sand blast cleaning or combination thereof in order to attain

desired surface quality as required by the specific primer paint.

Surface shall be prepared to achieve grade Sa 2 1/2 of SIS Standard by sand blasting.

After surface preparation, equipment shall be painted with

• Two coats of two-pack air drying epoxy polyamide resin based red oxide zinc

phosphate primer as per IS 2074 : 1992.

• One coat of two-pack air drying high-build epoxy resin based intermediate

paint with micaceous iron oxide (MIO).

• Two coats of two-pack air drying epoxy polyamide enamel paint suitably

pigmented.

• Dry film thickness (DFT) of each coat of primer, intermediate and finish Paints

shall be 30, 100 and 40 microns respectively.

01.13.01.06 Paint Application

Paint shall be applied in accordance with manufacturer’s recommendations as

supplemented by this specification. The work shall generally be carried out as per IS

1477 (Part II).

50

Paint shall not be applied in rain, wind, fog or at relative humidity of 80% and above or

when the surface temperature is below dew point resulting in condensation of moisture.

Paint shall generally not be applied when the ambient temperature is 50 C and below.

Each coat of paint shall be continuous, free of pores and of even film thickness without

thin spots.

Each coat of paint shall be allowed to dry sufficiently before application of the next

coat to avoid damage such as lifting or loss of adhesion.

01.13.01.07 Colour Code

Shades of finish coat to be applied shall be as per IS 5 and of wide acceptability in

water supply works. Prior approval shall be taken from the Purchaser after placement of

order before adopting final colour shade for any particular item being painted.

01.13.01.0 8 Warranty and Guarantee

The Tenderer shall warrant for satisfactory performance of the equipment and material

for a period of 18 months from the date of the last dispatch or 12 months from the date

of commissioning of equipment whichever is earlier. The Tenderer shall replace/repair

within seven days of receiving the notice at his own cost any defective parts in the

equipment of his own manufacture or those of his sub-contractors.

The Tenderer shall guarantee various performance parameters as specified below

The pressure drop across the strainer under semi-clogged condition shall not exceed

5mWC.

The size of suspended solids in outlet of strainer shall not exceed 1000 microns.

In the event of a shortfall in the guaranteed performance figures the Purchaser shall

have the right either

To agree to a financial settlement with the Contractor, or

To reject the plant as a whole and in such event the Contractor shall have to pay back

the whole sum paid to him on this account.

51

01.14. STAINLESS STEEL FLEXIBLE HOSES.

01.14.01 Equipment Specification

1. Type of Hose : Single Stainless Steel wire braided corrugated flexible hose

assembly SS AISI 304, fitted with SS female swivel fittings at

both ends (Nut nipple) suitable for connecting pipes. As per BS:

6501 Part-I with type B flexibility. Alternatively cam lock

connection can also be offered.

2. Size : By Bidder

3. Suitable for pipe : By Bidder

Internal diameter

4. Test pressure : 18 kg/cm2

5. Operating pressure : 12 kg/cm2

6. Frequency of bend : Single

7. Design temperature : Normal : 40 to 50 deg C/

Maximum : 110 deg C

8. End connection : Female swivel end on both sides (Nut nipple) suitable

for connecting pipes having:

52

01.15. RUBBER EXPANSION JOINTS:

01.15.01 Equipment Specification

Material specification:

Rubber Expansion Joints shall be made of high grade abrasive resistant natural rubber

compound reinforced with adequate numbers of piles of heavy cotton duck, rayon cord,

impregnated within rubber compound and further reinforced with square metal ring

embedded in it. The outer exposed surface of rubber expansion joints shall be given a

coating of synthetic/neoprene rubber and further painted with chlorinated rubber based

paint. Rubber expansion joints will be suitable for design temperature of 5O deg C and

for handling clear water. Rubber expansion joints shall absorb vibration, shock and

axial compression of 10 mm, axial elongation of 10 mm and lateral movement of 10

mm.

Control unit:

One set of control unit (stretcher bolt assembly) consisting of 2/3 nos. limit rod

(material IS:3657 Gr. 6.6), Stretcher Bolt, Triangular Plate (material IS:226), Nuts

(material IS:1363 Gr. 6.O) Steel Washer and Rubber Washer of durometer hardness of

100deg Centigrade +/- 5 deg Centigrade.

The control unit shall be made suitable to make RE joint and no. of limit rod matched

against each.

01.15.02 Technical Parameters of Rubber Expansion Joints

1.

Sl. No Size Qty

1 DN

2 DN

2. Test pressure : 18 kg/cm2 or as per relevant standards

Max. Pressure (operating) : 12 kg/cm2

Design pressure : 16 kg/cm2

Burst pressure : ……. kg/cm2

3. Leak test : 18 bar(g), joint shall be kept immersed in water

bath to check leak tightness

4. Length : As per relevant Standard

5. Tie rod : 3 tie rods per Rubber Expansion

Joint

53

6. Material of construction

Body : Vendors to specify

Cover : Vendors to specify

Tie rod : Vendors to specify

7. Design temperature : Normal 40 Deg Centigrade

Max 80 Deg. Centigrade (Worst Case)

8. End connection : Carbon steel forged loose flanges at both ends,

with dimensions as per ANSI-B 16.5

54

01.16. SLUICE GATES

01.16.01 Equipment Specification

Sluice gates shall be supplied as per IS:3042-1965. Gear box arrangement shall be of

open type for small size and closed type for sizes above 400mm size.

All assembly bolts/studs, nuts, anchor, bolts and washers are acceptable in stainless

steel construction to AISI:304/ AISI:410.

Sealing of single face is acceptable. Accordingly leakage test shall be performed to

ensure committed leakage for seating head only applied for unseating side.

Item Nos. of all the gates shall be punched on the gate (at an easily identifiable place)

before dispatch.

01.16.02 Data for Design of Sluice Gates

i) Type of Mounting : Wall mounted type with head stock. Headstock shall

have geared handle for operation.

ii) Spindle type : Rising Spindle.

iii) Design code : Sluice gates shall be generally as per IS:3042; 1965.

Wedges shall be provided on the sides to ensure

maximum water tightness.

01.16.03 Material of Construction

i) Head Stock, wedge, : CI, IS:210, Gr: FG 200 -1993

Shutter, Gate frame,

Stop-nut. ii) Hinge Pin & Stem : SS, AISI 410

iii) Seat facing/sealing : Naval Brass IS:291, Gr:2 -1989

face.

iv) Fasteners : SS, AISI 304/410

v) Anchor bolts : SS, AISI 304/410

vi) Stem Coupling : SS AISI 410

55

vii) Gate Frame, Shutters, : CI , IS:210, Gr: FG200-1993

Ungeared head stock body,

Wall Guide Brackets, Stop-Nut

viii) Hand wheel : M.S.

01.16.04 Shop Testing & Inspection

Testing and inspection of the materials shall be carried out at the works of the

Contractor or his sub-Contractor during manufacturing and on final product to ensure

conformity of the same with acceptable criteria of Technical Specifications, approved

drawings, authenticated manufacturing drawings and reference Indian/International

standards.

The Contractor shall furnish Quality Assurance Plan (QAP) for each equipment and

material for Employer’s/Consultant’s approval prior to start of manufacturing.

A leakage test shall be performed by the manufacturer to ensure committed

leakage for both seating and unseating head.

Tests to be conducted at the shop for various assemblies/sub- assemblies of

equipment shall include, but not be limited to the following:

• Material test.

• Tests during manufacture/fabrication.

• Dimensional checking.

• Hydraulic test at the shop.

For each of the items being manufactured/supplied, the following test certificates and

documents, as applicable, in requisite copies including original shall be submitted to the

Inspection Agency. All test certificates shall be endorsed by the manufacturer and the

Contractor with linkage to the project, purchase order and acceptance criteria.

Raw materials identification and physical and chemical test Certificates for all materials

used in manufacture of the equipment

01.16.05 Pressure test Certificates:

Inspection at manufacturers’ works shall not relieve the Contractor of responsibility for

replacing at his own cost any defective part/material and repairing equipment for

defective workmanship that may be discovered at site at a later date.

56

01.16.06 Shop Painting

Immediately after casting and before machining, all cast iron parts shall be thoroughly

cleaned and before rusting commences, these shall be coated with at least two coats of

bituministic rust proof compound of approved quality. The final coats shall be applied

to the exterior surfaces, excluding machined portions, after assembly & testing.

01.17. C.S FITTINGS - SPECIFICATION

01.17.01 Black Fittings

Black fittings upto 50NB shall be Socket welded type type as per ANSI B 16.11.

Black fitting above 50NB shall be Butt welded type as per ANSI B 16.9.

Black fittings of sizes above 40NB shall be forged fitting suitable for welding and

conforming to ANSIB16.9. Black fittings shall be supplied with ends suitable for

butt-welding.

01.17.02 Material of Construction for Fittings:

Sl.

No.

Size Material of construction

1 DN15 To DN50 FORGED

BENDS

MATERIAL A105, Class 3000 (SW)

2 DN65 TO DN250 FORGED

BENDS

MATERIAL A234 Gr WPB, Sch 40

BW

3 DN300 TO DN450 FORGED

BENDS

MATERIAL A234 Gr WPB, Sch 30

BW

4 DN500 AND ABOVE FORGED

BENDS

MATERIAL A234 Gr WPB, Sch 20

BW

5 FORGED SOCKOLETS MATERIAL A234 Gr WPB, Class 3000

(SW).

6 FORGED REDUCERS UPTO

DN250

MATERIAL A234, Gr WPB, Sch40

7 FORGED REDUCERS FROM

DN250 TO DN400

MATERIAL A234, Gr WPB, Sch30

8 FORGED REDUCERS FROM

DN500 & ABOVE

MATERIAL A234, Gr WPB, Sch20

01.17.03 Flanges

All flanges shall be slip on raised face type as per Table 11 of IS:6392:1971(RA 88).

Material of construction for the flanges shall be Carbon Steel as per IS:2062:1992. All

bolts and nuts shall be black hexagonal type as per IS:1364 Part 1&3-1992 Class

4.6/4.0.All gaskets shall be as per IS: 638 -1979 (RA 1993).

57

01.18. FIRE HYDRANTS - SPECIFICATION

01.18.01 General

a) Landing valve/yard hydrant shall be as per IS: 5290-1993, Type-A and should have

TAC approval.

The hose cabinet shall be fabricated out of 18 SWG M.S. sheet. The size of the

cabinet shall be suitable for holding one/two hoses as indicated under schedule of

quantities and shall be hanging type for indoor installation & supporting type on

pedestals for out door installations. The two sides and back of the hose cabinet shall

be made from sheet by pressing. The top shall have pressed edges slightly

projecting outside to prevent water (while cleaning etc) from entering the cabinet.

The cabinet shall be fitted with two doors having glass panel. The thickness of glass

shall not be less than 3mm. The door shall be provided with a knob and a lock with

duplicated key on the body of the door with a glass cover. The glass of the key box

shall be easily replaceable. Suitable hooks, etc. shall be provided in the cabinet to

hold the hose reels etc. mentioned above. Suitable wall mounting bracket shall be

provided with the cabinet. The word `key' shall be painted (on the body of door)

with an arrow pointing the glass of key cover. The hose cabinet shall be painted red

from outside and white from inside.

The tenderer shall provide a fully dimensioned general arrangement drawing

indicating materials of construction, relevant specifications, etc.

01.18.02 Internal Hydrants/ Yard Hydrants:

Sl.

No

Description Material of

construction

1. Gun metal Fire Hydrant Landing valve, Oblique type,

single outlet type of 75mm flanged inlet, 63mm female

bronze coupling with instantaneous outlet with hand-

wheel complete with blank cap and chain etc. as per

IS:5290-1993, Type –A,

Material of

construction shall be

LTB2 as per IS:318-

1981

Alternatively SS/

aluminum alloy.

2. M.S. Matching flange DN 80 (slip-on type , PN16 rating)

with nuts, bolts and gasket for the above hydrants as per

IS:6392,1971,(R.A.1988), Table-18.

Carbon Steel Gr:2A of

IS 2002.

3. Wall Mounting type M.S. Hose cabinet size

(600mmx450mmx250mm) fitted with double door glass

front panel suitable for holding the following. (The hose

box shall have handle with lock, bracket for holding hose

and branch pipe, a hammer and a key box ) :-

Material of

construction shall be

18SWG MS sheet to

IS:2062.

58

Sl.

No.

Description Material of

construction

3.1 Rubberized fabric reinforced rubber lined (RRL)

flexible hose of 15 meter length as per IS: 636 -1988,

each fitted with instantaneous male coupling at one end

and female coupling at the other end.

The couplings shall be

of LTB2 construction

as per IS:318-1981

Alternatively SS/

aluminum alloy

3.2 One 25 mm nozzle Material of

construction shall be

LTB2 as per

IS318:1981

3.3 One branch pipe as per IS:903 -1984 (R.A -1990) - do -

3.4 One nozzle spanner as per IS:903-1984 (R.A-1990) Material of

construction shall be

“Steel Gr34C4 or

Steel Gr: 40C8 as per

IS: 5720 (Part- 2/

Sec-1).

1

ANNEXURE - I

01. DATA SHEETS

01.01 HORIZONTAL PUMP SETS

HORIZONTAL PUMP SETS

1 No. OF PUMPS

2 TYPE OF PUMP

3 PUMP MODEL

4 PUMP OPERATING CHARECTERISTICS

A RATED CAPACITY OF EACH PUMP (m3/HR)

B TOTAL DYNAMIC HEAD(TDH) AT RATED CAPACITY

(MWC)

C SHUT OFF HEAD, (mWC)

D SPEED (NOMINAL) RPM

E PUMP EFFICIENCY AT RATED CONDITIONS (%)

F PUMP SHAFT POWER AT RATED CAPACITY (KW)

G REQUIRED NPSH (mWC)

H TYPE OF GLAND SEALING

I MODE OF CONNECTING PUMP TO MOTOR

J DIRECTION OF ROTATION

K IMPELLER DIAMETER (MIN / RATED / MAX) mm

L TYPE OF END CONNECTION

• SUCTION FLANGE BORE mm :

• DISCHARGE FLANGE BORE mm :

• DRILLING STANDARD FOR FLANGES

5 MATERIALS OF CONSTRUCTION

A IMPELLER

B CASING

C CASING RING

D SHAFT

E SHAFT SLEEVE

F GLAND

G BASE FRAME

H COMPANION FLANGES

2

01.02 VERTICAL PUMP SETS

VERTICAL PUMP SETS

1 No. OF PUMPS

2 PUMP MODEL

3 PUMP OPERATING CHARECTERISTICS

A RATED CAPACITY OF EACH PUMP (m3/HR)

B TOTAL DYNAMIC HEAD(TDH) AT RATED CAPACITY

(MWC)

C SHUT OFF HEAD, (mWC)

D SPEED (NOMINAL) RPM

E PUMP EFFICIENCY AT RATED CONDITIONS (%)

F PUMP SHAFT POWER AT RATED CAPACITY (KW)

G TYPE OF GLAND SEALING

H MODE OF CONNECTING PUMP TO MOTOR

I DIRECTION OF ROTATION

J IMPELLER DIAMETER (MIN / RATED / MAX) mm

4 TYPE OF END CONNECTION

• DISCHARGE FLANGE BORE mm :

• DRILLING STANDARD FOR FLANGES

5 COLUMN LENGTH (mm)

6 TYPE OF SHAFT SEAL

7 BEARINGS

TYPE :

MAKE :

8 QUANTITY OF BEARING PROVIDED

9 TYPE OF LUBRICATION REQUIRED

10 COUPLINGS TYPE

11 BASE FRAME WITH HOLDING DOWN BOLTS AND

NUTS

12 COMPANIAN FLANGES

3

13 MATERIALS OF CONSTRUCTION

A IMPELLER

B CASING

C CASING RING

D SHAFT

E SHAFT SLEEVE

F GLAND

G BASE FRAME

H COMPANION FLANGES

I COLUMN PIPE

J SUCTION STRAINER

01.03 MOTORS OF HORIZONTAL PUMP SETS

MOTORS OF HORIZONTAL PUMP SETS

1 RATED KW AT 50 DEG.C

2 RATED KW AT 40 DEG.C S1 DUTY (KW)

3 RATED VOLTAGE & SYSTEM CONDITIONS

4 FRAME SIZE

5 CLASS OF INSULATION

6 RATED SPEED & DIRECTION OF ROTATION

7 FL CURRENT

8 OPERATION AT 80% RATED VOLTAGE FOR 5

MINUTES

9 NO.OF STARTS/HR (EQUALLY SPREAD)

PERMISSIBLE

10 OPERATION AT 80% RATED VOLTAGE FOR 5

MINUTES

11 No OF STARTS/Hr (EQUALLY) SPREAD PERMISSIBLE

12 LOCKED ROTOR WITHSTAND TIME AT 110% RATED

VOL

13 PULL UP TORQUE

14 PULL OUT TORQUE

4

01.04 MOTORS OF VERTICAL PUMP SETS

1 MAKE

2 RATED KW AT 50 DEG.C

3 RATED KW AT 40 DEG.C S1 DUTY (KW)

4 RATED VOLTAGE & SYSTEM CONDITIONS

5 FRAME SIZE

6 CLASS OF INSULATION

7 RATED SPEED & DIRECTION OF ROTATION

8 FL CURRENT

9 OPERATION AT 80% RATED VOLTAGE FOR

5 MINUTES

10 NO.OF STARTS/HR (EQUALLY :

SPREAD) PERMISSIBLE

11 No OF STARTS/Hr (EQUALLY) SPREAD

PERMISSIBLE

12 LOCKED ROTOR TORQUE

13 PULL UP TORQUE

14 PULL OUT TORQUE

15 MAX WINDING TEMPERATURE BY

RESISTANCE METHOD

16 DEGREE OF PROTECTION OF ENCLOSURE

5

02. ON-LINE AUTOMATIC FILTER

02.01 On line Simplex Filter in Gearbox cooling Water System(Primary Circuit).

Sl.No. Description Parameters

1. Flow m3/hr

2. Inlet Pressure Kg/cm2

3. Line Size

4. Sieve Size Micron

5. Operation Simplex type

6. Qty.

02.02 On line automatic Filter in B.F.Shell Water supply System (Primary circuit).

Sl.No. Description Parameters

1. Flow m3/hr

2. Inlet Pressure Kg/cm2

3. Line Size

4. Sieve Size Micron

5. Operation Automatic Self

cleaning Filter

6. Qty.

02.03 On line automatic Filter in Tuyere Water Supply System (Primary circuit).

Sl.No. Description Parameters

1. Flow m3/hr

2. Inlet Pressure Kg/cm2

3. Line Size

4. Sieve Size Micron

5. Operation Automatic Self

cleaning Filter

6. Qty.

02.04 On line automatic Filter for Hearth Spray( open industrial water).

Sl.No. Description Parameters

1. Flow m3/hr

2. Inlet Pressure Kg/cm2

3. Line Size

4. Sieve Size Micron

5. Operation Automatic Self cleaning

Filter

6. Qty.

6

02.05 Partial stream on-line Filter for Secondary Circuit water of PHE

(open industrial circuit).

Sl.

No.

Description Parameters

1. Flow m3/hr

2. Inlet Pressure Kg/cm2

3. Line Size DN

4. Sieve Size Micron

5. Operation Automatic Self cleaning Filter

6. Qty.

7

03. COOLING TOWER

03.01 GENERAL

Name of manufacturer

Manufacturer’s plant location

Tower model no.

Type of tower

Number of cells

Capacity per cell , m3/hr

03.02 TOWER OVERALL DIMENSION, m

a) Length

b) Width

c) Height ( to fan deck )

03.03 DIMENSION OF EACH CELL, m

♦ Length

♦ Width

♦ Filled height

♦ Louvre height and angle from horizontal

03.04 BASIC PARAMETERS PER CELL

Rated water flow, m3/hr

Design wet bulb temp., deg.C

Approach, deg.C

Cooling range at rated flow , deg.C

Evaporation loss at rated condition, m3/hr/cell

Temp. of leaving air

♦ Dry bulb

♦ Wet bulb

Total air area, m2/cell ( full plan area)

Total louvred area, m2/cell

Dry air flow per m2 of air area, (G) kg/h/m2

Water flow area, m2/cell

Water flow rate per m2 of water area, (L),

m3/h/m2

8

03.05 TOWER FILL

Material

Type of treatment

Expected life, years

Type of flow,

No. of full and partial decks

Equivalent fill decks

Equivalent fill height, m

Number, splash bars in direction of air flow

( cross -flow)

Size, splash bars, mm ( nominal)

Splash bar position

Splash bar spacing

♦ Horizontal

♦ Vertical

Fill stringer size, m

Total fill volume, m3/cell

Wetted surface area, m2/m3

Splash surface area, m2/m3

Fill performance characteristics

Total vertical water fall height, m

Solidity ratio of fill, cross flow

03.06 FILL SUPPORT AND GRIDS

Type

Material

Size

03.07 GRID SUPPORT FRAME

Type

Material

Type of treatment, if any

9

03.08 FAN

Type and Make

No. of fans / cell

Diameter of fan, m

No. of blades per fan

Blade tip clearance, mm

Hub diameter, m

Net discharge area, m2

Blade width at ¾ radius, m

Capacity, m3/min per fan

Speed , rpm

Fan stack

♦ Height , m

♦ Type ( std or velocity recovery)

♦ Stack exit air velocity, m/sec

(based on NDA)

Air density at fan, kg/m3

♦ Dry air

♦ Mixture

Fan pressure, mmWC

♦ Louvres

♦ Filling

♦ Eliminator

♦ Velocity head

♦ Total head

♦ Velocity recovery, if any

♦ Net head

Fan efficiency, %

♦ Static

♦ Overall

Brake power Kw at motor shaft

Power at fan shaft, Kw per shaft

Motor size, Kw

Material of construction

♦ Blades

♦ Hub

♦ Fan shaft

Type of connection with gearbox shaft

10

03.09 REDUCING GEAR UNIT

Make

Type

Model No

Reduction ratio

Rated input, Kw

Service factor at design point

Material of construction

♦ Gear

♦ Shaft

♦ Enclosure

“No load loss” at gear box

Gear box oil

♦ Type

♦ Trade name

♦ Approximate quantity of oil required

in each box, m3

Details of bearing

Efficiency

11

03.10 DRIVE SHAFT

Diameter, m

Approximate length, m

Material of construction

Type of coupling

Type of support

03.11 DRIVE MOTORS

Make

Voltage

Phase

Frequency

Rated, Kw

Shaft / pull out torque

Full load current, Amp

Starting current, Amp

Efficiency

Class of insulation

Type of enclosure

Degree of protection

Recommended DOL

Starting current

Speed, rpm

03.12 HOT WATER DISTRIBUTION SYSTEM

Type

Nozzle spacing

Elevation, inlet above curb, m

Water pressure required at battery limit

No. of nozzles per cell

03.13 COLD WATER BASIN

Basin dimension, m

( L X W )

Basin curb elevation, m

Normal water level, m

Maxi. Water level, m

Basin invert level, m

Effective capacity, m3

12

03.14 VALVE DETAILS

Make Cell inlet

water control

valve

Header isolating

valve

Desludging

valve

Other

Type

Number &

size

Material of

construction

♦ Body

♦ Trim

03.15 MATERIAL OF CONSTRUCTION

Structural

member

Casing and

louvres

Inner and

outer casing

Fan stack

Distribution

header

Hardware

03.16 MATERIAL HANDLINGSERVICES

Type

Capacity

Material of

construction

Protection

against

corrosion

13

04. SLUICE GATES

Sl.

No.

Unit Size of

Gate

Length of spindle from

C-L of water-way upto

the top of platform

(In mm)

Qty

Nos.

Remark

Ungeared

/Geared

1. G.C.P Pump-

House

2. Blast Furnace

(Clear Water

Circuit)

3. Blast Furnace

(Contaminated

Water Circuit)

4. Pig Casting

Machine

5. Turbo Blower

Station Pump

house

14

05. SOFT WATER PLANT

05.01 PRESSURE FILTER/ACTIVATED CARBON FILTER

To be filled in by tenderer Sl.

No

Description

Pressure

Filter

Activated

Carbon Filter

1. Shell dimension: diameter and length, mm

2. Vessel design code adopted

3. Design pressure, kg/cm2

4. Hydro-test pressure, kg/cm2

5. Guaranteed output between two

successive backwash

6. Guaranteed effluent quality

7. Flow rate, m3/h

Normal

Maximum

Backwash

Rinse

8. Head loss through bed, mWC

Normal

Maximum

Backwash

Rinse

9. Filter Materials

Type

Size of grading, mm

Quantity per filter, m3

Life of filtering material year

10. Bed depth and free board provided

11. Time required for backwash

12. Time required for rinse

Minimum

13. Material of construction of vessel

14. Type and material of inlet distributor and

under drain system

15. Material and detail of nozzle

16. Filter shell and dished End thickness, mm

17. Flooded weight, kg

18. Empty weight, kg

19. Compressed air requirement and pressure

20. Time of air scouring in min.

15

05.02 BASE EXCHANGERS

Sl.

No.

Description To be Filled in by

Tenderer

1 Nos. offered

2 Sheel Dimension dia x ht

3 Design pressure, kg/cm2

4 Vessel design code adopted

5 Thickness of

a) Dished end

b) Shell

6 Regeneration Cycle

7 Guaranteed output between two successive

regenerations (12 hr cycle)

8 Flow rate, m3/h

Normal

Maximum

Backwash

Regeneration

Slow Rinse

Fast Rinse

9 Head loss through bed, mWC

Normal

Maximum

Backwash

Regeneration

Slow Rinse

Fast Rinse

10 Time required for regeneration

Back wash

Salt Injection

Slow Rinse

Fast Rinse

Total time

11 Type of resin

12 Make of resin

13 Volume of resin

14 Depth of resin bed

15 Free board provided

16 Guaranteed life of resin

16

Sl.

No.

Description To be Filled in by

Tenderer

17 Expected rate of deterioration of resin per year

18 Regeneration level by 100% NaCl per m3 of

resin

19 Exchange capacity of resin for above

regeneration level

20 Guaranteed quality of out-let water

(a) total hardness as CaCo3 ppm

(b) pH

21 Quality of 100% NaCl required per

regeneration Kg

22 Type and material of inlet regeneration,

distributor and under drain system

05.03 Blowers

Sl.

No

Description For filter

For degasser

tower

1. Nos offered

2. Make

3. Capacity, m3/min

4. Total head, mWC

5. Rpm of blower

6. kW of motor

7. Rpm of motor

8. Type of coupling

9. Size of suction/ discharge, mm

10. Make of motor

11. Material of construction

12. Total weight, kg

05.04 Brine measuring tank / brine saturator

Sl.

No.

Description To be Filled in

by Tenderer

1 Capacity

2 Size

3 Material of construction

4 Thickness of plate

5 Thickness of lining

06 PLATE HEAT EXCHANGERS

Sl Description T.S. Requirement

No. UnitPrimary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

1 General

1.1 No. of Plate Heat Exchangers Nos.

1.2 Manufacturer

1.3 Model NO./Type Plate Type

1.4 Whether single or double pass Single

2 Design

2.1 Design Pressure Bar(g)

2.2 Design Temperature Deg.C

2.3 Heat Load Kcal/h

2.4 LMTD(Corrected) Deg.C

3

Guaranteed Performance for each heat

exchnager

3.1 Flow Rate Each PHE / m3/h

3.2 Inlet Temperature Deg.C

3.3 Outlet Temperature Deg.C

a) In Fouled Conditions

b) In clean conditions

3.4 Total Pressure drop across heat exchanger Bar(g)

from inlet to oulet

a) For Design flow

b) For 110% of design flow rate

4 Heat transfer and fluid flow data

4.1 Film heat transfer Coefficient Kcal/hrm2°C

4.2 Fouling factor m2hr°C/Kcal

4.3 Overall fouling (Min 20%) / m2hr°C/Kcal

4.4 Overall Heat Transfer Coefficient Kcal/hr m2 °C

Blast Furnace Shell

Plate Type

Plate Type Plate Type Plate Type

Single Single Single Single

Tuyere Circuit Stove Circuit

Gear Box Cooling

Circuit

"(c)2005,MECON LTD. All Rights Reserved". 1

Sl Description T.S. Requirement

No. UnitPrimary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Blast Furnace Shell Tuyere Circuit Stove Circuit Gear Box Cooling

Circuit

a) In Fouled Conditions

b) In clean conditions

4.5 Total Effective heat transfer area per heat m2

exchanger

4.6 Average Velocity m/s

a) Through Ports 4-5 m/s

b) Through plate channels <2m/s

4.7 Pressure drop in ports Bar(g)

a) In Clean conditions

b) In Fouled conditions

4.8 Pressure drop in channels Bar(g)

a) In Clean conditions

b) In Fouled conditions

4.9 Maximum diffrential pressure pressure

between hot and Cold Bar(g)

5 Heat transfer plates

5.1 Area of each plate m2

5.2 Dimension (width X height) mm X mm

5.3 Thickness mm

5.4 Material and chemical Composition AISI316 AISI316 AISI316 AISI316 AISI316 AISI316 AISI316 AISI316

5.5 Number of plates per heat exchanger Nos.

5.6 Maximum number of plates that can be

accommodated in the heat exchnager Nos.

5.7 Type of corrugation Herring bone

5.8 Maximum plate pack length mm

a) as per 5.5 above

b) as per 5.6 above

5.9 Average spacing between two plates <4mm

5.1 Number of contact points for each plate Nos.

"(c)2005,MECON LTD. All Rights Reserved". 2

Sl Description T.S. Requirement

No. UnitPrimary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Blast Furnace Shell Tuyere Circuit Stove Circuit Gear Box Cooling

Circuit

5.11 Hold up volume of each passage m3

5.12 Port Size(Diameter) mm

6 Plate Gaskets

6.1 Type Moulded Single Piece

6.2 Material and chemical Composition NBR

6.3 Thickness of Gasket 4.5 to 5mm

6.4 Hardness of Gasket > 75 Shore

6.5 Expected life of gasket min. 5 Years

7 Carrying bar

7.1 Type of construction S.S.

7.2 Number per heat exchanger One No.

7.3 Size

7.4 Material CS- IS2062, SS 304 Cladding

8 Guiding bar

8.1 Type of construction SS claded

8.2 Number per heat exchanger One No.

8.3 Size

8.4 Material CS- IS:2062, SS 304 Cladding

9 Frame plate

9.1 Type of construction

9.2 Material IS:2062, Gr:B

10 Pressure plate

10.1 Type of construction

10.2 Material IS:2062, Gr:B

11 Supporting columns

11.1 Type of construction

11.2 Material IS:2062, Gr:B

12

Clamping/Gasket composition

arrangement

"(c)2005,MECON LTD. All Rights Reserved". 3

Sl Description T.S. Requirement

No. UnitPrimary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Blast Furnace Shell Tuyere Circuit Stove Circuit Gear Box Cooling

Circuit

12.1 Type of arrangement Tie rod type

12.2 Bolt size and material ASTM 193 B7

12.3 Nuts size and material ASTM 194 2H

13 Inlet and Outlet Nozzels

13.1 Size mm

13.2 Rating ANSI 150#

13.3 Facing and drilling standard ANSI B 16.5

13.4 Flange material CS, IS:2062, Gr:B

13.5 Are all nozzles counter flnages, bolts, nuts

and gaskets etc. included in the offer

14 Cleaning frequency of the heat

exchanger for assumed factor Months

15 Is backwash necessary

16 Are all auxiliaries and accessories

included in the offer

17 Local temperature indicators

17.1 Manufacturer & Type

17.2 Number per heat exchanger Nos.

17.3 Dial size mm

17.4 Range

17.5 accuracy

17.6 Material of construction

18 Local Pressure gauges

18.1 Manufacturer & Type

18.2 Number per heat exchanger Nos.

18.3 Dial size mm

18.4 Range

18.5 accuracy

18.6 Material of construction

ASTM 194 2H ASTM 194 2H

By Purchaser By Purchaser

By Purchaser By PurchaserBy Purchaser

By Purchaser

ASTM 194 2H

By Purchaser

ASTM 194 2H

By Purchaser

Tie rod type

ASTM 193 B7

Tie rod type

ASTM 193 B7

Tie rod type

ASTM 193 B7

Tie rod type

ASTM 193 B7

"(c)2005,MECON LTD. All Rights Reserved". 4

Sl Description T.S. Requirement

No. UnitPrimary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Blast Furnace Shell Tuyere Circuit Stove Circuit Gear Box Cooling

Circuit

19 Differential pressure gauges

19.1 Manufacturer & Type

19.2 Number per heat exchanger Nos.

19.3 Dial size

19.4 Range

19.5 accuracy

19.6 Material of construction

20 Relief and other valves(if applicable)

20.1 Location

20.2 Type and size

20.3 End details

20.4 Materials

a) Body

b) Trim

20.5 Pressure rating

20.6 Number per heat exchanger No.s

20.7 Manufacturer

21 Are all counter flanges, bolts, nuts and

gaskets etc. for all terminal points

included in the offer

22 Are all heat exchangers supplied with

necessary foundation plates, anchor

bolts sleeves, inserts, lifting lugs etc. as

specified

23 Shot tests & Inspection

23.1 Whether all tests and inspection as detailed

in specification/quality plan will be carried

will be carried out

23.2 Hydrostatic test

Ref. 13.5 Ref. 13.5 Ref. 13.5

By Purchaser By PurchaserBy Purchaser

Ref. 13.5

By Purchaser

"(c)2005,MECON LTD. All Rights Reserved". 5

Sl Description T.S. Requirement

No. UnitPrimary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Primary

(Soft)

Secondary

(industrial)

Blast Furnace Shell Tuyere Circuit Stove Circuit Gear Box Cooling

Circuit

a) Test Pressure 23 bar(g)

b) Test duration 30 min.

23.3 Whether all tests checked for cracks and

other defects bt penetration method?If not ,

what percentage is checked?

23.4 whether hardness test will be conducted for

plate gasket

24 Details of painting

24.1 Exterior surface

a) Surface preparation

b) Primer As per SA 2-1/2 of

c) Finish Preparation Swedish Standard

24.2 Interior surface SIS-055900

a) Surface preparation

b) Primer

c) Finish Preparation

25 Weight of each heat exchanger

a) Empty Kg

b) Flooded Kg

26 Overall Dimensions

Lenth X Breadth X height mm x mm x mm

27 Withdrawl apace

28 Other information (if any)

"(c)2005,MECON LTD. All Rights Reserved". 6

01.19 STANDARDS TO BE FOLLOWED

01.19.01 Pumps

IPSS-1-05-002-1989 Specification for Single stage horizontal split

casting centrifugal pumps for raw water.

IPSS-1-05-003-1977 Specification for Single stage horizontal end suction

centrifugal pumps for raw water.

IPSS-1-05-004-1977 Specification for multi stage centrifugal pumps for

raw water.

IPSS-1-05-005-1977 Specification for vertical spindle centrifugal pumps

for raw water.

IPSS-1-05-006-1979 Specification for single stage horizontal split casing

centrifugal pumps for emulsion, slurry, & scale

bearing water.

IPSS-1-05-007-1979 Specification for single stage end suction

centrifugal pumps for emulsion, slurry, & scale

bearing water.

IPSS-1-05-008-1979 Specification for vertical spindle centrifugal pumps

for emulsion, slurry, & scale bearing water.

IPSS-1-05-009-1979 Specification for pumps handling corrosive liquids.

IPSS-1 – 05 – 010-1981 Sump pump unit.

IPSS-1 – 05 – 020-1985 Specification for self priming single stage end

suction centrifugal pumps for coal tar.

IPSS-1 – 06 – 001-1996 (R-1) Foot valves

IPSS-1 – 02 – 054 Specification for pneumatic sump pump- ejector

type

IS: 11745,1986 Technical supply condition for positive

displacement pumps-reciprocating.

IS : 1520 Horizontal centrifugal pumps for clear, cold & fresh

water.

IS : 5120-1977 Technical requirement for roto-dynamic special

purpose pumps.

IS : 5600-1970(R-2002) Sewerage and drainage pumps.

IS : 5659-1970 Pumps for process water.

IS : 5639-1970 Pumps handling chemical & corrosive liquids.

IS : 1710-1989 Vertical turbine pumps for clear, cold and fresh

water.

IS : 8034 -2002 Submersible pumpsets for clear, cold & fresh

water.

IS : 8418-1999 Horizontal centrifugal self priming pumps.

IS : 9801 Slurry pumps

IS : 6536-1972 Pumps for handling volatile liquid.

API : 610 Centrifugal pumps for general refinery purpose.

BS : 599 British standard for method of testing pumps.

ASME Power test Centrifugal pump, power test code. Code PTC 8.2

BS : 5316 } Code of acceptance tests for centrifugal, mixed flow

and axial flow pumps.

IS : 9137 }

IS : 9201-1987 Pumps for handling slurry

01.19.02 Pipings

ASTM A106 Code for boiler pipe lines

ASTM B 31.1 Code for pressure piping

ASTM B 16.5 Steel pipe flanges

IS 1239 Part I&II Mild steel tubes & fittings

(Part-I-2004, Part-II-1992)

IBR Indian Boiler Regulation with latest amendments.

BS 806 Ferrous piping system for and in connection with

land boilers.

BS 1414 Steel wedge gate valves, flanged & butt-welded

ends.

BS 1873 Steel gate & globe, stop & check valves for

petroleum industries.

BS 5351 Steel ball valves

API 600 Specification for steel valves.

API 5L Specification for pipelines.

IS : 778 -1984 Copper alloy gate, globe & check valves for general

purpose.

IS : 780- 1984 Sluice valves for water works purpose

IS : 14846

IS : 3589-2001 Electrically welded steel pipes for water, gas, and

sewerage (Dn 200 to 2000 mm)

IS : 5312, Part-I-1984 Part I Swing check type reflux valves

IS : 5290-1993 Landing valves

IS : 909 Underground fire hydrant

IS : 6392-1971 Steel pipe flanges for water, oil, steam etc.

IS : 781-1984 Bib taps

IS : 3042-1965 Sluice gates

IS : 1703-2000 Ball valves including floats for water supply

purpose

IS : 4038-1986 Foot valves

IS : 636 -1968 Rubber hose delivery coupling, branch pipe &

fighting.

IS : 903-1993 Fire hose delivery coupling, branch pipe & nozzles

IS : 913-1968 Water hose of rubber with braided textile

reinforcement

ANSI ; B 16.9 Butt welded fittings

ANSI: B 16.11 Forged steel fittings : Socket welded & threaded

BS : 1560 Steel pipe flanges and flange fittings

BS : 3601 Steel pipes & tubes for pressure purpose – ordinary

duty carbon steel

BS : 3602 Steel pipes & tubes for pressure purpose- carbon

steel high duty

BS : 3603 Steel pipes & tubes for pressure purpose- carbon 7

alloy steel

BS : 3604 Steel pipes & tubes for pressure purpose -ferritic

alloy steel

BS : 3059 Steel boiler and superheated tubes

BS : 1952 Copper alloy gate valve for general purpose

BS : 5154 Copper alloy globe check & valve for general

purpose

BS : 3808 Cast & forged steel Flanged, screwed

API : 602 & socket welded wedge gate valve

BS : 5150 wedge and double disc gate valves for general

purpose

BS : 1868 Flanged/butt welded type swing check valves

IS : 1978-1982 Line pipes

IS : 5504-1997 Spiral welded pipes

IS : 2712-1998 } Specification for compressed

BS : 2815 } asbestos fiber jointing

IS : 6157 -1981 General instruction for testing of valves &

equipment’s

IS : 1536 -2001 Centrifugal cast (spun) pressure pipes

IS : 1537-1976 Vertically cast (spun) pressure pipes

IS : 1538 -1993 CI fittings for pressure pipes for water, gas &

sewage

IS : 2002-1992 Boiler quality plates

BS : 5157 Steel gate (parallel slide) valves for general purpose

BS : 5352 Steel wedge gate, globe & check valves for

petroleum industry

BS : 2871 Copper & copper alloy tubes

BS : 4504 Flanges & bolting for pipes, valves & fittings

BS : 5146 Specification for inspection & test of steel valves

BS : 5155 CI & carbon steel plug valve for general purpose.

A : 106 Seamless carbon steel pipes for high temperature

service

A : 335 Seamless ferritic alloy steel pipe for high

temperature service.

A : 234 Steel fittings

IS : 10611-1983 Steel wedge gate valve butt welded/flanged end

IS : 9338-1984 CI globe valve

IS :10459-1983 Taper plug type valve for general purpose.

IPSS-1-06-014 Guidelines for moist fuel gas lines

IPSS-1-06-010-1994 Specification for C. S. non-return valve

IPSS-1-06-016 Colour coding for pipe lines in steel plant

IPSS-1-06-023 Guideline for painting of steel surface

IPSS-1-06-030 Heat resistant anti-corrosive paints

IPSS-1-06-022 Specification for hose nipples

IPSS-1-06-004 Specification for control valves and actuator

IPSS-1-06-021-1986 Specification for steam trap

IPSS-1-06-017-1986 Specification for selection of steam traps.

IPSS-1-06-026 Specification for taper plug type valve for general

purpose.

IPSS-1-06-002 GM globe, gate & check valves

IPSS-1-06-005-1983 MS pipes

IPSS-1-06-007 CI gate valve (NB 50 to 300 mm)

IPSS-1-06-022 CI gate valve (NB 350 - 1200 mm)

IPSS-1-06-008-1994 Cast steel gate valve (rising spindle)

IPSS-1-06-009 CI non-return valve

IPSS-1-06-013-1984 Welded steel pipe for general use

IPSS-1-06-019-1987 Air release valve

IPSS-1-06-020-1995 Fabricated pipe fittings

IPSS-1-06-027 Safety valves and relief valve

IPSS-1-06-001-1996(R-1) Foot valves

IPSS-1-06-003-1995(R-1) centrifugally cast (spun) iron pipes for water and

sewage.

IPSS-1-06-006-1985 MS tubular cast steel and malleable CI fitting.

IPSS-1-06-012 Butterfly valves for gas application.

1

02. GASES AND LIQUID FUELS

02.01 Regulations

The entire interplant and in shop pipelines shall conform to the provisions of relevant

Indian statutory regulations, wherever applicable, such as :

- Indian Safety Rules

- Static & Mobile Pressure Vessels Rules

- Indian Petroleum Regulations

- Indian Explosives Manual

- The Carbide of Calcium Rules

- Indian Boiler Regulations

The Contractor shall have to obtain clearance/ approval of all the relevant drawings/

documents from such statutory bodies.

02.02 Pipe Laying

Routing and layout of piping system shall be as per good engineering practice. Following

factors shall be taken into consideration while designing piping system.

• All functional requirements shall be fully satisfied.

• Adequate clearance is provided for equipment and operating personnel.

• Easy access for operation and maintenance of piping component.

• Convenient supporting points for piping, equipment, valves, etc.

• Adequate flexibility for thermal expansion / movements.

• Aesthetics and neat appearance.

Pipe Laying for Fuel Gases, Industrial Gases, Liquid Fuels, Compressed Air and Steam

01. The gas pipes installed along building wall should not cross window and door way.

02. While laying high pressure gas pipes along the walls, the later should be fire-proof. In

doing so, the gas pipes should be laid along solid walls or above the windows of upper

floors of plant buildings.

2

03. When gas pipes are installed along external walls of buildings below window ways,

installation of flange, thread joints and also installation of accessories is not allowed.

04. Gas pipe may be laid along with pipes of water, steam, air, etc. and also with oxygen on a

common support provided conditions stipulated under various clauses are followed.

05. The following conditions shall be observed when installing gas pipes with other pipes :

a) Additional pipes on existing gas pipes will be allowed to be laid only with the

permission of concerned plant personnel.

b) In each case, the gas pipes and supporting structures shall be checked with due

consideration for additional loads and practical state of the metal structure of gas

pipes.

c) When installing with pipes carrying corrosive fluids they shall be kept at least 500

mm below or by the side of the gas pipe at a distance of 500mm.

If flange joints are provided on pipes carrying corrosive liquids, it is necessary to

mount protective baffle plate against falling of corrosive liquids on gas pipes and

their supports.

d) The associated gas pipes at the places on gas pipes where valves and other devices

are mounted, should be kept at a minimum 800 mm distance from the main pipe.

e) Drainage of the associate pipes should be laid to one side at a distance so that

condensate does not fall on gas pipes/ its accessories, supporting structures and

their elements, etc.

06. The branch line should generally be installed outside building along roof wall. Branch

line having diameter less than 500 mm may be laid inside shop building.

07. Branch line from gas main entering into building through building wall should pass

through casings. Internal clearance between casing and pipe should be suitably filled up,

wherever required.

08. Gas branch line from gas main passing through roof covering should have circular

opening. For this purpose, a circular opening should be made on roof and a taper hood

should be provided on the branch line above the roof for protection from rain.

3

09. Shop headers (except headers of By-product Plant) should be mounted at a height having

minimum ground clearance of 4500 mm, when laying them outside the building wall.

10. Layout of gas consuming units in various shops should be such that it is possible to bring

the gas pipes above ground.

11. Gas pipes of coke oven, natural gas and also their mixtures with blast furnace gas may be

installed in channels and casings, in the region of gas supply to furnace and other

consuming units.

The following conditions should be observed for this purpose :

a) Clearance between wall and bottom should be at least 400 mm, and for gas

pipes of 200 mm and below clearances should not be less than the gas pipe

diameter.

b) Installation of flanges, threaded joints and accessories (except accessories for

removal of condensate on a pipeline) is not allowed when it is laid in a

channel. The number of welds on such gas pipes should be restricted to a

minimum.

c) Installation of gas pipes with air pipes to gas consumer units is allowed to be

laid in channels.

d) Channels with gas pipes should not cross other channels, In case, it is

unavoidable, air tight tie-plate should be made and gas pipe should be placed in

casing. Ends of casing should be taken out beyond the limit of tie-plate by 300

mm at both ends.

e) Channels should have provisions for natural ventilation.

14. Gas pipes in buildings should be located at places convenient for servicing, inspection

and repair. It is not allowed to lay gas pipes at places where there are chances of damage

due to shop transport.

15. For gas lines installed in hot zone, it is recommended to provide protection against

overheating of gas pipes.

16. It is allowed to fasten gas pipes to frames of furnaces, boilers and other units provided

these frames are checked for strength by calculations.

4

17. Gas pipes are not allowed to pass through buildings producing or having materials liable

to explode or burn and building of power distributing devices and substations and

ventilation chambers and through buildings, in which gas pipe may be damaged by

intensive corrosion.

18. Gas pipes should not cross ventilation doors, air exhauster, flue pipes and also gas pipes

should not be installed in insufficiently ventilated space and in underground buildings.

19. Installation of high pressure gas pipes below main working platforms of shops is not

permitted.

20. Gas pipes along bridges should be made of seamless pipe and laid in the open at a

horizontal distance of one metre from ends of pavements for passing of people and it

should be within reach for servicing. Supporting elements of the bridge should be

accordingly checked for loads from gas pipes. Laying of gas pipes in channels of bridges

is not allowed. All welding joints of gas pipes in the area of their attachment to bridge

should be radio graphed.

21. Gas pipes passing through walls, ceilings, and other structures of buildings of

construction shall be encased in a steel pipe having inside dia at least 50 mm more than that of

the oxygen pipe. The Gas pipe shall have no joints in the section at such crossings. The gap

between the gas pipe and the outer pipe shall be filled with non/inflammable material, but

allowing vertical and horizontal movement.

22. The laying of moist fuel gas pipelines shall be as per IPPS: 1-06-014-95

23. Pressure pipe work for gases and liquid fuels generally shall be routed overhead. All

overhead interplant pipe work to be routed such that they will have a minimum clearance

of 6.0m between bottom of supporting structures / pipes and road / railway track. The

pipelines laid over hot tracks shall have a minimum clearance of 10.0m, in case of using

protective shields in these places, this clearance shall be reduced to 6.0m Buried

pipes, wherever laid, shall be provided with a minimum earth covering of

1200mm in areas subject to temporary loads and minimum earth covering of 1000mm in

areas not subject to temporary loads, unless otherwise specified.

24. For the pipelines laid on roof, the distance from the external edge of the pipe to the roof

shall be at least 0.5m.

5

25. All shop headers, except for gravity fluids, shall be generally routed along columns in

multiple rows at a height 4 to 6m above floor level. The connections to equipment shall

be taken through suitable covered floor trenches for shops at ground floor and for

basements, for elevated operating floors, the equipment pipe work connection may be

taken below the floor level. All isolated single pipe connections to equipment shall be

buried in the flooring / equipment foundations. Pipe work from basement and oil cellars

to main equipment shall be routed in pipe tunnels / trenches with adequate spacing for

easy maintenance. All pipe trenches shall be covered by chequered plate or by concrete

slabs.

26. The bleeder pipes for purging lines and other exhaust pipe work shall be routed upward

along columns / gable ends and / or walls to a minimum height of 4,000mm above the

roof level / platforms.

27. For the gas pipelines laid along the building walls, the clearance between the gas

pipelines and the wall shall be adopted so as to ensure the possibility for maintenance of

the gas pipelines. The gas pipelines laid on the walls must not cross the window and door

openings.

28. Branch pipes from the headers to the building through walls and the roof shall be

encased.

29. Gas pipelines shall be earthed. When laid under the high voltage lines, a protective sheet

guarding shall be provided above the gas pipelines. The guarding shall be earthed. The

earthing resistance must be not over 10 ohm.

30. Platforms, access ladders, hand railing, etc. shall be provided for operation and

maintenance of valves, instruments and controls. Manholes and hatches shall be provided

for access inside the gas pipelines.

31. At all the places of regular maintenance (gate valves, throttle valves, orifice plates,

hatches, manholes, bleeders, etc.) if located at a height of over 2.5m from the

maintenance level, provision shall be made for stationary platforms with the railings and

stairs / ladders.

32. To ensure the condensate drainage, the gas pipelines shall be laid with a gradient of about

0.005 towards the water drains.

6

Condensate drains shall be equipped with bleeders.

33. Flash back arrestors shall be provided in each section of the pipe work for acetylene and

LP gas to prevent flame propagation or pressure surges. They may be of hydraulic /

cartridge type flash back arrestors or back pressure valves.

34. All branch pipes from main header shall be connected through a hydraulic arrestor.

35. Shut-off globe valves shall be provided on both the inlet and outlet sides of the arrestor

and unions shall be provided for repair or replacement, if required.

36. Oxygen pipelines may be laid on either side of the fuel gas line as per the following

norms.

Oxygen Pressure in

Kg/cm2

Diameter of Oxygen

pipe mm

Permissible gap in

mm

Upto 0.1 Upto DN 500 300

Upto 0.1 Above 500 600

0.1 to 16 Upto 500 800

16 to 35 Upto 200 800

Continuous installation is not allowed if the oxygen pressure is more than 16 Kg/cm2 and

diameter of pipe is more than 200mm and also if the oxygen pressure is more than 35

Kg/cm2 for any size.

Minimum clearances of overhead oxygen pipelines (surface to surface)

i) Explosion Hazardous shops : 3 meters clearance

ii) Railway tracks : 3 meters

iii) Railway bridge and platform : 3 meters

iv) Roads : 1.5 meters upto

embankment

7

v) High voltage Transmission lines

A. Parallel to pipelines : 10 meters

B. Crossing the pipelines upto 20kv : 3meters

35 to 150kv 220kv : 4 meters

vi) To place of hot metal tapping and

Source of open fire : 10 meters

vii) Insulated L.T cables : 0.5 meters

Bare conductor L.T : 1.0 meters.

02.03 Design Parameters

Design pressure for various categories of piping shall be as follows :

Low Pressure Fuel gas piping : 1.25 Times Maxi. Operating

Pressure

( Up to 1500 mm WC MOP) But not less than 2000 mmWC minimum

All other gas piping : 1.25 Times Maxi. Operating

Pressure

Steam piping : 1.5 times Maximum Operating

Pressure.

Design temperature for all fluids shall be maximum working temperature of fluid. In case

of ambient temperature, design temperature may be taken as 60 deg C for piping exposed

to sun and 45 deg C for indoor piping.

Flow rate for design purpose shall be taken as peak flow rate for the respective section. In

case of branches to individual consumers, peak flow rate for the consumers shall be

considered. For common branches and main headers, peak flow rate based on

consumption pattern/ diversity factor may be used for pipe sizing.

Future augmentation of flow rate for common piping shall also be taken into

consideration for pipe sizing.

02.04 Selection of Pipe Size

• Pipelines shall be sized by limiting the gas velocity in the pipeline as per Table 08-01.

• Peak flow rate based on the distribution pattern shall be considered for sizing of

pipes.

8

• Sizing shall be based on actual flow rate at worst combination of parameters i.e.

lowest pressure and highest temperature.

• In case recommended velocity is dependant on diameter range, after initial sizing,

velocity should be re-checked and if required size should be recalculated.

• Nearest higher standard pipe size shall be selected after calculation.

For critical applications, pipe sizes should be re-checked after pressure drop calculations

and availability of required pressure at consumer point. If required pipe size may be

increased to meet the pressure drop criteria.

TABLE 08-01

RECOMMENDED VELOCITIES IN CARBON STEEL PIPES

A: Low Pressure Fuel Gases

Gas Velocity, m/sec (maximum) Sl.

No

Nominal Pipe

Dia – (mm) BF & BOF

Gas

CO Gas, Natural

Gas

Mixed BF &

Corex Gas

Remarks

1 20 – 80 2 2 2

2 100 - 250 3 - 4 4 – 5 4 –5

3 300 – 500 5 - 6 6 – 7 5 – 7

4 600 – 800 6 – 7 7 – 8 7 - 8

5 900 – 1200 8 - 10 9 – 12 8 – 11

6 1300 – 2000 11 - 18 13 – 20 12 – 19

7 > 2000 20 - 25 23 - 28 21 - 27

B: Medium Pressure & High Pressure Gases

Medium Pressure Range

(kgf/cm2 g)

Gas Velocity, m/sec

(maximum)

Remarks

Up to 6 8 –10 See Note 1

6 - 16 12 – 16

Nitrogen, Argon,

Compressed Air,

Instrument Air 16 - 40 Up to 20

Up to 16 12 See Note 2 Oxygen

16 - 40 8

LPG Up to 3 8

Acetylene Up to 1.2 8 Up to DN 25

Liquid Fuels All Pressures 1.5

9

C: FOR STEAM

Average Velocity, m/sec Sl.

No

Fluid Condition

Up to

DN 50mm

DN 50 to

DN 150mm

DN 200mm

and above

Remarks

1 SATURATED

AT SUB-

ATMOSPHERI

C PRESSURE

- 10 – 15 15 – 20

2 SATURATED

AT 1 TO 7

Kgf/cm2 (g)

15 – 22 20 – 33 25 – 43

3 SATURATED

ABOVE 7

Kgf/cm2 (g)

15 – 25 20 – 35 30 – 50

4 SUPERHEATE

D UPTO 7

Kgf/cm2 (g)

20 – 30 25 – 40 30 – 50

5 SUPERHEATE

D ABOVE 7 TO

35 Kgf/cm2 (g)

20 - 33 28 – 43 35 - 55

02.05 Expansion and Flexibility.

All Pipe work shall be designed to provide sufficient flexibility against thermal expansion

to prevent development of undesirable forces and moments at points of connection to

equipment, at anchorage or at guide points.

As far as possible flexibility shall be provided by planning route with change of direction

or by the use of bends, loops or off-sets..

Whenever self-compensation can not be achieved by pipe routing, provision for thermal

expansion shall be made by providing expansion loops or expansion joints as per

following criteria :

• U loops shall be provided for all low pressure fuel gas piping up to DN 300 size

and high pressure piping for all sizes.

• For high pressure piping, where U-loop is not possible, bellow type expansion

joint shall be provided. Bellow type compensators shall also be provided in low

pressure gas lines.

10

While locating the expansion joints following guidelines should be followed:

• Bellow compensators should be located preferably in the center of two fixed

points.

• U-Compensators should be located in between two fixed points with variation in

pipe lengths in the ratio of 1:2 (max).

• Gland Compensators should be located near the fixed supports to facilitate

smooth functioning.

• Bellow and gland compensators shall have flanged connection with pipes

U-loop Compensator

U-loops shall be provided in piping system using elbows/ bends as per piping material

specification.

U-loops shall be in horizontal plane and loops for many pipes running in parallel may be

provided at same location parallel to each other.

Loops shall be in the same plane as the pipe route. However, in some cases, where there

may be obstruction due to other parallel pipes, U-loop plane may be raised to clear the

pipes by providing bends.

Loops in vertical plane can be provided in exceptional cases if horizontal loop is not

possible due to layout considerations. Provision shall be made in piping for draining of

condensate, venting, etc.

Bellow Compensator

Bellow type expansion joints shall be made from SS sheet and can be single or

multi layer with number of convolutions.

Loads due to Compensators

Loads on anchor points due to bellow compensators shall be considered based on the

feed back from supplier / manufacturer.

11

02.06 Load data for designing

- The pipeline stockades shall be designed to take all vertical (dead) as well as

horizontal loads.

- 20% extra load (vertical and horizontal) shall be considered for the design of

structural and civil work to accommodate future pipeline on the stockades.

- Vertical load shall comprise of the following :

Platforms

Condensate collected in pipeline

Dust deposition on pipeline

Valves, compensators & fittings

Supports, ladders, etc.

- Live load on platform shall be taken as 500 kg/m2

- Platform shall be provided at the following locations :

• Location of valves

• Location of compensators

• Location of condensate drain installation

• Water seals and tanks for water seals

• Purging and vent connections

• Manholes

• Instruments

Following norms shall be followed for calculating the condensate load of gas mains:

Sl.

No.

Pipe Dia

(mm)

Height of filling of pipe

cross-section with

condensate (mm)

Filling in cross – section (%)

1. Upto 500 Full 100

2. 600 – 1400 500 88 – 35

3. 15oo and above 500 - 800 30 - 14

Condensate drain installation shall be located at approximately every 100 m length of the

pipeline.

12

Load due to dust deposition shall be as follows :

- 50 Kg per m2 area on pipelines at a distance within 100 m from blast furnaces.

- 25 Kg per sq metre area on pipelines at a distance between 100 to 500 from blast

furnaces.

Horizontal load along the axis of the pipeline shall comprise the following:

- Load due to thermal expansion

- Load due to internal gas pressure

- Load due to friction (sliding of pipes on supports)

Horizontal load transverse to the axis of the pipelines shall comprise the following:

- Load due to wind pressure

- Load due to component of gas pressure at branch connections

- Load due to component of force arising from thermal expansion or at change of

axis in plan.

For calculating load due to thermal expansion the co-efficient of linear expansion for

mild steel shall be taken as 0.012 mm/deg.c/ m.

Internal gas pressure for coke oven and blast furnace gas shall be taken as 2000 mmWC

(g) (Test pressure for the gas pipeline).

Co-efficient of friction for steel to steel shall be taken as follows :

Sliding support : 0.30

Roller support : 0.10

Ball support : 0.10

IS:875 shall be applicable for calculating the wind load on the stockades.

IS:1873 shall be applicable for calculating seismic load.

The unsupported span of pipeline between two supports shall be calculated on the

following basis;

I) Maximum deflection in the span should not exceed 1/600 of length of the span.

II) Maximum stress in pipe should not exceed the limit as per design codes.

III) Maximum permissible spans are indicated below:

13

Table – 08.02

Maximum permissible spacing between pipe supports

Nominal Pipe size, mm Maximum span for

Liquid service, m

Maximum span for

other services, m

25 2.0 2.5

40 2.5 3.0

50 3.0 4.0

65 3.5 4.0

80 5.0 4.5

100 5.0 4.5

150 5.0 6.5

200 6.0 7.0

300 7.0 9.0

500 - 13.5

600 - 15

1000 - 18

1500 and above - 24

02.07 Valves and measuring devices

Valves shall be provided on pipe work for isolation of pipe sections and equipment,

control of pressure, flow and level of fluids, venting, draining, pressure relief, etc. They

shall be suitable for the service conditions in all respects and located suitably considering

ease of operation and maintenance. Generally the following practice shall be followed;

14

- Stop valves:

On all pipelines both at the sources and consumers also in the branch pipes to

individual buildings and shops with a nominal diameter of 100 mm and above (if

required, for smaller diameter as well).

- Isolating and by-pass valves for flow meters, filters, etc.

- Check valve on all pipelines requiring unidirectional flow.

- Quick action safety shut-off valve on fuel oil, gas/ air lines to furnaces and heaters

as well as before each consumer or group of consumers.

- Pressure regulating valves with isolating, by-pass and relief valves for all pressure

reducing installations.

- Manual drain valves at low points and manual vent valves at all high points of

pipe work.

- Regulating valves with integral pressure gauge for all oxygen outlet points, fuel

gas outlet, etc.

- All valves shall be provided with the operating handle/ lever/ wrench within easy

reach. Where necessary, operating platforms shall be provided. Valves located in

inaccessible locations such as basements, tunnels, etc. Shall have remote actuation

by means of electric motors, solenoids, etc.

- For fluid lines with working pressures over 16 atg, valves of diameter 300 mm

and above shall be provided with by-pass arrangement, unless otherwise specified

in technical specifications.

- Shut-off valves of dia 500 mm and above as well as shut-off valves of all

diameter with remote or automatic control shall be provided with electric drives .

- To facilitate operation of manually operated valves, adequate gearing and

handling arrangement shall be provided, wherever necessary

- All gas branch pipes from the in shop collector to the consumers shall be provided

with bleed valve arrangement comprising two gate valves in succession with a

bleeder in between. After the second gate valve (upstream), a provision shall be

made for installation of a blank flange.

- Shop pipe work for all production and ancillary units shall have metering of flow

and pressure at the battery limits.

- Sectionalising of pipe work for fuel gases such as coke oven gas, blast furnace

gas, mixed gas and converter gas will be provided to facilitate maintenance work.

This may be achieved by water seals, goggle valves, spectacle blinds or patented

gas tight isolators.

15

02.08 Condensate Disposal

Fuel gases as well as other gasses contain moisture and other condensable impurities

which get separated during fluid transportation through piping system, effective

condensate removal system should be incorporated to prevent accumulation of

condensate in pipes which otherwise may cause obstruction to proper gas flow and

excess live load to the pipe/ structure.

All piping for gasses containing moisture etc. like BF / Coke oven / BOF gas, Mixed gas,

Compressed air, Steam & Natural gas are laid with gradient / slope. A slope of 5mm per

meter run shall be provided for the above pipelines. In case of space constraint to

accommodate slope, it may be reduced to 0.003 particularly for in shop piping. For

straight length of pipeline, low / high points should be located generally at a distance 100

meters. However, in no case it should exceed 300 meters.

Condensate drain points shall be provided at all low points. In case of low pressure gas

lines, automatic drainage system though seal pots shall be provided.

For compressed air lines and steam lines, automatic condensate / steam traps shall be

provided.

Condensate Drain Arrangement for Low Pressure Gases

i) Drainage shall be provided at all the low points of gas pipes carrying moist gases

for condensate removal. Disposal of condensate shall be through seal pots/

condensate drain installations.

ii) Distance between any two drain points of a gas pipe within a radius of 100 meters

from gas cleaning plant should not exceed 60 meters.

iii) Drainage system for outdoor gas networks should be located in open air with

necessary accessibility for operation.

iv) Pipes for condensate removal from inter shop gas pipes of blast furnace gas in a

radius of 400 m from gas cleaning plant should be at least 80 mm diameter. For

pipelines beyond 400 m and also for gas pipes for other moist gases, diameter of

condensate removal pipes should not be less than 50 mm.

v) Separate seal pots shall be provided for different gasses.

vi) Removal of condensate from branch line from inter shop gas pipe and inshop gas

pipe should be carried out in separate condensate seal pots.

16

vii) Minimum height of the water seal in the condensate seal pot shall exceed the

maximum working pressure of gas by 500 mm, but this height in no case shall be

lower than 2000 mm.

If necessary, the height of water seal can be increased by adding more than one

seal pot in series. However, number of such seal pots shall not exceed three.

Further base plate of seal pot shall have minimum thickness of 16 mm.

While installing common seal pot for a number of gas pipe, height of water seal

should exceed by 500 mm the maximum working pressure in any of the

connected gas pipe.

viii) Design of condensate seal pots should ensure protection against leakage of

harmful gases into building by providing vent of adequate height on the seal pot.

ix) Condensate seal pot shall be provided with purging facilities.

x) Installation of condensate seal pot for inshop gas network is allowed inside the

buildings.

Condensate Drain Arrangement for Medium pressure High pressures gas

i) Condensate disposal for gases having higher line pressure have to be done by

using adequate pressure seal pots.

ii) In a high pressure seal pot the metallic float is utilized for disposal of condensate

and prevent leakage of gas from the pot.

iii) The seal pot should be air tight and wall thickness should be decided on the line

test pressure.

iv) Condensate coming out of seal pot should be discharged into phenolic sewerage

line or in a reservoir provided locally.

17

Steam Traps / Moisture Traps-

At low points in steam & compressed air pipeline steam traps / moisture traps with

strainer assembly will be provided to drain out the condensate. Selection of steam trap

shall be as per IPSS: 1-06-039 – 02. Installation of steam traps shall be as per IPSS: 1-06-

037

02.09 Bleeders/ Vents

Bleeders shall be provided on all the gas handling devices and pipelines for purging and

venting any section of the gas pipeline. The purging bleeders of pipelines carrying

different fluids, separated by gate valves, are not allowed to be combined into one

bleeders. The bleeders shall be taken above the gas pipeline or above roof of the building

by at least 4 m, but not lower than 12 m from the ground level. Bleeders on shop roofs

shall be located away from roof monitors.

i) Bleeder/vents shall be provided for purging / venting any section of the pipeline.

Bleeders shall be located generally at all high points in the piping system. Bleeder

/ vents shall also be provided at down stream / upstream of isolating devices & U-

seals.

ii) All vents shall discharge at a safe height into atmosphere. The vents shall be

above the operating floor / platform for vent valve or roof of the building 4m, but

not lower than 8 meters from the ground level. In the presence of the aeration

monitors on the roof of the building, the vents shall be located so as to eliminate

the possibility of purged gas getting inside the premises.

iii) On straight lengths bleeder/vent shall generally be provided at an interval of 100

meters.

iv) All vents shall have T piece/cowl with bird screen preferably at the top. For

isolation of bleeder/vent pipe flanged gate valve of rising stem type shall be

provided. Sampling points (DN 25) below isolation valve with lubricated taper

plug valve shall be provided in the line to monitor gas samples at the time of

purging.

v) Vent pipes of different gases shall not be connected through a common vent.

vi) Recommended sizes of bleeder / vent pipes corresponding to gas pipe diameter

are indicated in Table – 08.03.

18

Table –08.03

RECOMMENDED SIZES OF BLEEDER / VENT PIPES

Pipe dia.

Bleeder pipe dia. DN (mm) DN

(mm) Low Pressure Fuel gas Natural gas/Corex Gas

20 - 20

25 - 20

40 - 20

50 50 20

65 50 20

80 50 20

100 50 20

150 50 25

200 50 25

250 50 25

300 50 25

400 80 50

500 80 50

600 80 50

700 100 80

800 100 80

900 100 80

1000 150 100

1100 150 100

1200 150 100

1300 150 150

1400 150 150

1500 200 150

1600 200 -

1800 200 -

2000 250 -

2200 250 -

2400 250 -

2500 250 -

2800 250 -

3000 250 -

3200 300 -

3500 300 -

19

02.10 Purging System

Piping system particularly piping for fuel gases is required to be purged with inert gas

prior to charging of gas as well as during shut down before any maintenance job.

System for feeding purge gas and venting of gas/ air from the piping system shall be

provided for all fuel gas piping.

i) Gas pipelines of blast furnace gas, coke oven gas, converter gas and mixed gas

shall be equipped with nitrogen or steam pipe connection with isolation valve .

The connection of nitrogen or steam pipeline to the gas pipeline shall be done by

means of flexible hose which shall be connected only during the period of

purging.

ii) Location of purge gas inlet points and vents shall be such that entire section of

piping can be purged with minimum dead space. Purging points shall be provided

at low points.

iii) Purging points shall not in any case be provided at bottom half of the gas mains.

iv) Purge points for fuel gas pipes upto DN 950 mm shall be of minimum DN 25 mm

same for pipes of DN 1000 mm & above shall be of minimum DN 50 mm.

02.11 VALVES AND ISOLATING DEVICES

Isolating devices shall be provided in piping system for isolation of pipe sections as well

as for isolation of all other mounted accessories for the purpose of operation and

maintenance. They shall be suitable for the service conditions in all respects and located

suitably considering ease of operation and maintenance.

Isolation valves shall be provided at the following locations:

• On all pipe lines both at the source and at consumer ends

• On all branch pipes to individual buildings and shops

• On all bleeder / vent pipes, purge gas inlet points, drain points, sampling

connections, etc.

• On all by-pass lines for large valve, regulators, filters, moisture traps etc.

• Instrumentation tapping points.

20

Relocation of isolation valves on request of CLIENT may be also be considered if

technically acceptable.

Other types of valves required for piping system include the following :

• Check-valve on all pipelines requiring only unidirectional flow.

• Quick acting shut-off valves on gas/ air lines to furnaces and heaters as well

as before each consumer or group of consumers.

• Pressure regulating valves for all pressure reducing installations, gas mixing

stations and flow control system.

02.11.01 Selection of Isolating devices :

The gas cut-off arrangement shall ensure the possibility of complete cut-off gas along

with fast and safe operation. Gate valves with rising stem shall be used normally for

isolation in piping system.

Pipe work for fuel gases such as Blast Furnace Gas, Coke Oven Gas, Converter Gas,

Mixed Gas with low operating pressure shall have some means of gas tight isolation of

sections of the pipe work to facilitate maintenance work. These may be water seals,

goggle valves, spectacle blinds, or gas tight isolators / slide plate valves, etc.

For sections where the gas tight isolating device can not be provided, provision to insert

blind flange at outlet of gate valve shall be made.

Sectionalizing / isolation for purging of fuel gas lines may be done with Spectacle blinds.

Gas tight butterfly valves may be used for isolation near consumption points requiring

frequent and quick operation. These can be valves with gas tight seating or eccentric

valves for gas tight isolation.

Emergency quick shut off valves shall also be double eccentric butterfly valves.

For fluid lines with working pressure over 16 kg/cm2 (g), valves of DN 300 and above

shall be provided with by-pass arrangement or depressurisation arrangement for pipe

sections.

02.11.02 Selection of Actuators for Isolating Devices:

Manually operated shut-off gate valves of size DN 300 to DN 450 for low pressure lines

shall have gear drive. For high pressure lines, gear operator shall be provided as per

manufacturer’s recommendations for limiting the operating torque to acceptable limits.

21

Gate Valves of size DN 500 and above shall be provided with electric actuators. Electric

actuators for fuel gas lines shall be of flame proof design if located in gas zone/inshop. In

the interplant area these actuators need not be flame proof. Position and torque limit

switches shall be provided on actuators. Manual over ride shall also be available in

actuators.

Goggle valves shall have electrical actuators for disc/ plate movement and electro

hydraulic drive for flange separation. Manual arrangement for valve operation shall also

be provided with gear and chain operation from convenient location. The hydraulic

power pack for the valve shall include one motorized pump and one manual pump.

Encased design goggle valve with vent should be used at locations closed to buildings.

Electrically operated gate valves for gas pipelines of smaller diameter are recommended

to be used only if they are incorporated in the automation scheme.

All valves located remotely, requiring frequent operation and / or with automatic control

shall be provided with electric drives, electro- pneumatic drive, solenoids etc.

02.12 Other Flow Components

02.12.01 Check Valves

Check valves are used in piping system where unidirectional flow is required check

valves can also used for stopping flow reversal incase of sudden stoppage of fluid flow

like in the pump discharge. For small size pipes below DN 50, lift check valves are used.

For DN 50 and above, swing check valves or dual plate check valve are used. Lift check

valves can used only in horizontal pipeline it should not be used in vertical pipeline. For

low pressure gas lines dual plate check valve are most suitable.

02.12.02 Pressure Regulating Valves

Irrespective of specified variations in upstream pressure, these shall maintain a reduced

constant pressure on the downstream side of pipelines on which they are mounted. The

valve shall be of globe / needle type, with material specifications, dimensional standards

etc. as per the relevant piping Material Specification(PMS) for the service for which the

valve is intended.

22

Self actuated pressure regulators shall be used for pressure reduction in service piping.

Spring loaded pilot operated regulators shall be used. In case precision control of pressure

is required. Dome loaded regulators with additional pilot spring loaded regulator for

pressurizing the dome may be used. For pressure regulators, maximum and minimum

available pressure upstream of regulator and desired range of outlet pressure with

maximum flow rate shall be specified.

For process lines where continuous regulation/ control of pressure or flow is required,

control valves shall be used.

1 For Compressed Air

Pressure regulators of sizes up to DN 50 shall be complete with a prefilter having 40

micron porous bronze filtering element in shatterproof plastic or glass container, pressure

regulator and pressure relief arrangement to prevent overpressure at downstream of the

regulator.

For higher sizes to meet larger flow rates, the pressure regulator shall be self actuating

type as per manufactures standards, but capable of meeting the service conditions and

duty specified.

2 For Steam

For sizes up to DN 50, pressure reducing valves of single seated diaphragm type having

in-built strainer, with screwed ends up to DN 20 for PN 10 and below and flanged ends

for higher sizes and for higher PN. Body of main and pilot valves shall be of carbon steel

/ alloy steel castings / forging, diaphragms shall be of stainless steel, internal springs of

stainless steel and pressure adjustment springs of spring steel.

For higher sizes to meet larger flow rates, the pressure reducing valves shall be as per

manufactures standards, but capable of meeting the service conditions and duty specified.

3 For Other Gases

For dry air, nitrogen and argon the pressure reducing valves shall be of stainless steel. For

oxygen service, the valve shall be of bronze construction and shall be degreased and

cleaned to meet the service requirements.

For acetylene and LP gas services, the pressure regulators shall have material for the

service. For acetylene, the materials of construction shall not have copper in excess of

70% by composition. (Refer IGC code).

23

Pressure regulators for large diameter gas lines shall comprise butterfly type valves

actuated by means of an oil hydraulic control system, which is actuated in turn by

changes in the preset downstream pressure through impulse pipe work.

02.12.03 Pressure Relief Valves

These shall be spring loaded type and shall automatically open when the pressure on the

pipelines, on which they are mounted, exceed preset values. The valves shall have end

connections and materials specified for throttling valves in relevant PMS.

Relief / Safety valves for steam service shall have IBR certification. Relief valves shall

have hand wheel / wrench for adjustment of preset value of relief pressure.

Pressure relief valves shall always be used on outlet lines from the pressure reducing

valves. Pressure relief valves shall be designed for full flow rate from pressure regulators.

Set pressure shall be 10 % higher than the maximum working pressure at outlet of

regulator.

02.12.04 Filters

Filters are installed in piping system before the pressure regulators/ control valves and at

consumer points depending on nature of fluid and technological requirements. For small

size pipes below DN 50, Y-type strainers with sintered/ wire mesh cartridge may be used.

For higher sizes, straight line mounted filters with removable cartridge shall be used.

Filter element can be of wire mesh, sintered material, woven fibers or other suitable type

as per process requirement. Filtration area shall be at least 500% of the inlet cross section

area.

Full flow rate, maximum working pressure, micron rating, allowable pressure drop,

material of body and mesh shall be specified.

02.12.05 Safety Shut-Off Valves

These shall shut-off in case the pressure on the upstream side of the valve becomes less

than preset values. The valves shall be of globe type for DN 50 and below and butterfly

type for sizes above DN 50; the material shall be suitable for service conditions. The

valves shall be actuated by electromagnetic or pneumatic device working in conjunction

with pressure switches located on the pipelines being safeguarded and shall include all

components required for its functioning.

24

02.12.06 Electrical continuity

Metallic electro static jumpers shall be provided at all locations on all flanged in case of

flammable gases and oxygen. This is to prevent accumulation of static electricity in pipe

sections. Piping system shall be suitably earth at a regular length of pipeline.

02.13 Measuring and Control Devices

Instrumentation and control devices are required for monitoring the fluid distribution

system, regulation of pressure and flow.

Flow measurement shall be provided at battery limit of all production and consuming

units, inlet/ outlet piping of storage installations, on surplus gas bleeder piping to flare

system etc. When orifice plates are used, proper care shall be taken in piping layout for

preventing accumulation of condensate by providing suitable slope or drain system.

Requirement of straight length upstream and downstream of flow sensors shall be

maintained as per instrumentation requirements. Normally the straight length

recommended is 10 times pipe dia before inlet and 5 times pipe dia after outlet of device.

Pressure measurement shall be provides at battery limits of production and consumer

units, at outlet of storage systems, inlet and outlet of pressure regulators/ controllers, etc.

Temperature measurement is provided at piping from gas cleaning plants and near

consumer installations.

Pressure and Flow Control valves are provided at gas mixing stations, main pressure

regulating stations, flare stack piping, inlet/ outlet piping of storage installations (gas

holders). For low pressure gas lines, butterfly type control valves are used. For high

pressure gases, globe valves may be used. Sizing of control valves is based on flow rate

and pressure parameters. In most cases, the control valve size is lower than the main pipe

size. Suitable reducers/ expanders shall be provided at inlet/ outlet of the control valves.

In case of piping with possibility of condensate accumulation, eccentric reducers shall be

used.

02.14 Special Considerations for Oxygen Piping

Filters should be installed in the oxygen pipeline system at the following points:

a) At the outlet of the oxygen plant.

25

b) Upstream of components having soft seating in contact with the oxygen stream

e.g. pressure regulator and control valves.

c) Upstream of components that have moving parts in contract with the oxygen

stream e.g. flow measuring and limiting devices.

Provision shall be made for safe and easy access for frequent cleaning and / or

replacement of the filter element. The larger capacity filters like (a) above should be

provided with differential pressure gauge for monitoring the condition and providing

indication for cleaning / replacement of the filter element. The filter bodies shall

preferably be of copper alloy or stainless steel and filter element of copper alloy or glass

cloth suitably earthed to the filter body with copper wires.

Two (2) or more pressure relief valves should be provided downstream of each set of

pressure reducing valves. One or more main relief valve(s) should be capable of

discharging 100% of the full oxygen flow and limiting the pressure within the defined

limits. The secondary relief valve should be sized to discharge the nominal leakage from

the pressure reducing valves. The relief valves should be positioned as close as possible

to the pressure reducing valves. The vent lines from the relief valves should be preferably

of stainless steel or copper.

Consideration should be given to providing of small size pressure equalisation bypass

isolation valves across large diameter isolation valves in large pipeline systems so as to

ensure safe pressurization of the downstream pipeline. Sonic velocities may occur during

the initial stages of valve opening with possibility of high velocity transport of material /

dirt particles in the system. If the valve opening action is rapid, there is also a possibility

adiabatic compression and heating of the oxygen specially if additional closed valves

exist downstream. The bypass pipe work and valve should be of copper or copper alloy.

Fire break sections may be installed in the oxygen pipeline to limit the propagation of

combustion in a steel pipeline. Fire break sections may be introduced immediately

downstream of the main isolation and throttling valves where the velocities can be high.

The fire break section will be either a length of copper pipe having the same inside

diameter as the main pipe with flanges fitted at the two ends which is installed between

the steel pipes or a copper insert tube made from copper sheet / tube and inserted inside

the steel pipe downstream of the valves. The copper insert tube is generally used in large

diameter steel pipelines.

In steel pipelines care should be taken to install isolation valves on straight sections of the

pipeline. Any pipeline component which is likely to cause a change in the flow pattern

like reducer, bend, tee or “Y” connection, orifice plate etc. should be at a distance of at

least four diameters away from the valve.

26

For cleaning of the gaseous oxygen pipelines after erection, provision for “pigging” will

be provided for pipelines having diameters upto DN 200. However, if the pipeline is

pickled and phosphated as per approved procedure, pigging of pipelines is not essential.

The bends on these pipelines will have a radius of 5 DN. DN 250 and above, extra care

will have to be taken regarding cleanliness of these pipeline during installation. For line

sizes DN 250 and above the bends will have a radius of 3 DN.

Gaseous oxygen pipe work shall preferably have butt welded pipe joints. To reduce

safety hazards the number of components should be kept to a minimum compatible with

the system requirements. Flange joints are to be used only for connection of the pipe to

the system components on the pipe work. Threaded joints and couplings should be

sparingly used.

02.15 Piping system shall be designed with high degree of reliability so that the systems

perform the duty of fluid handling without structural or functional failure under most

adverse condition of plant operation anticipated. All piping systems shall be designed

with sufficient corrosion and stress margins to ensure a life time without failure, not less

than the life of the plant. 7000 complete cycle of operation shall be considered for stress

analysis purpose. Piping system shall not impose reactions on equipment terminals

exceeding permissible limits even under adverse operating conditions. Personnel injury

from discharge of hot fluids from drains, steam traps, hot pipes or exposures to pipe

vibrations shall be guarded against.

01. Pipes shall be sized for minimum pressure drops and considering the velocity

limitation for various types of fluids.

02. Adequate flexibility shall be provided in the pipelines to keep stresses and reactions

in the system arising due to thermal expansion or other effects within limits. Where

the piping terminates at an equipment or at the terminal point of a system, the

reactions and thermal movement imposed by piping on the equipment or the system

concerned shall be well within the limits specified.

03. If cold springing of pipleline is used, care shall be taken in determining the location

and amount of cold spring gap. Cold spring gap shall be located at points where the

bending and torsional moments are minimum. Use of cold spring gaps less than

10mm shall not be acceptable and cold spring gaps above 100mm shall be avoided.

All outdoor piping exposed to sunlight carrying fluid at a temperature less than 800C

shall be designed considering thermal expansion corresponding to 800C and empty

pipe as one of the operating conditions although not necessarily the worst.

27

04. All piping shall have butt welded connections with minimum of flanged joints for

connection to vessels and equipment to facilitate erection and maintenance. All high

pressure steam valves and accessories shall have welded connections. Standard

fittings shall be used wherever practicable. Unless otherwise specified, for all welded

lines with pressure above 4 kg/cm2 g and / or temperature above 2000C, branch

connections with branch sizes upto 25% of welded mains shall be made with special

forged steel welded fittings.

05. Bends for pipes for oxygen service shall have a radius of not less than three times the

nominal pipe dia unless otherwise specified.

06. In general pipes having size 50mm and above, are to be joined by butt welding and

40mm below by socket welding / screwed connection. Threaded joints shall have to

be seal welded except for galvanized pipes where Teflon sealing tapes shall be used.

For galvanized pipeline, pipe joints which are to be made before galvanising shall be

of welding type. Those joints which are to be made after galvanising shall be either

flanged or screwed type. As far as practicable, whole fabricated piping assemblies

shall be galvanized at a time in order to minimize the number of joints to be made

after galvanising.

07. All pipelines shall be provided with drain connections, generally at the lowest point

for removing accumulated condensate or water and line draining. The drains piping

shall have drain pockets and isolation valves. Trap stations shall be provided where

necessary. Lines shall be given proper slope towards the drain points. Drip legs on

mainson line dia 150mm or over shall be at least 75% of the main dia with a depth

twice the dia of the main or 600mm minimum from the centre line of the main to the

trap off take unless otherwise specified. Drip legs on mains smaller than dia 150mm

shall be full dia of the line. All drip legs for fluids which may deposit undesirable

liquid or solid matter shall have full dia flanges for the bottom cover.

08. Pipe supports, anchors, restraints

- In general pipe supports, restraints, braces or anchors shall be located at those points

in the building or outdoor where provision has been made for the loads

imposed. Loads at the supporting points or restraints shall be determined

sufficiently early and provisions shall be made in the building or outdoor

structures for pipe supports. The Tenderer shall locate, design, supply and erect

all the supplementary steel structures to properly secure and support all pipe

hangers, supports, restraints, etc.

28

- Provision shall be made for support of piping which may be disconnected during

maintenance work. All large pipes and all long pipes shall have at least two supports

each arranged in such a way that any length of piping or valve may be removed

without any additional supports being required.

- Supports, guides and anchors shall be so designed that excessive heat is not

transmitted to the building steel. Supporting steel shall be of structural quality.

Perforated, strap, wire or chain shall not be used. Support components shall be

connected to support steel by welding, bolting or clamps. Bolt holes shall be drilled

and not gas cut. Structural steel work for supporting shall be designed on the basis of

a maximum design stress of 1265 kg/cm2. Pipe attachments coming in direct contact

with pipes having surface temperature above 4000C shall be made of alloy steel. Use

of insulating materials like asbestos between pipe clamp and pipe surface to meet the

above temperature limitation shall not be permitted. The maximum spacing between

two consecutive supports shall be not more than as specified. Pipe hangers and

supports shall be capable of supporting the pipelines under all conditions of

operation. They shall be capable of supporting the pipelines under all conditions of

operation. They shall allow expansion and contraction without over stressing the

piping system or overloading the terminal equipment due to variation in supporting

effort. Rigid supports or hangers shall be permitted only for pipes with small

movements. For hot lines, spring hangers shall be used. The maximum permissible

load variation on the terminals of sensitive equipment between hot and cold

conditions shall be limited to 6%. Variability in load between hot and cold conditions

expressed as a percentage of the design load shall be taken as the criteria for spring

selection for spring hangers. Variable spring hanger shall be set at cold conditions so

that they take design load under operating condition after the designed thermal

expansion has taken place.

Spring shall be encased in suitable cages and the hangers shall be provided with spring

locking arrangement, external load and movement indicator and turn buckles for load

adjustment. All the rigid hangers shall be provided with turn buckles for vertical length

adjustments. Hangers rods shall be subjected and designed for tensile loads. At locations

of high axial or lateral movement, suitable arrangement shall be provided to permit the

swing. The swing from vertical position shall be within 40. Double nuts and locknuts

shall be used for hanger rods and bolts in all cases. Hangers shall be designed so that

they can not become disengaged by movements of supported pipe.

- The supporting structures at each support points shall be designed for the highest of

the following loads to take into account the extra load during hydraulic testing.

- 1.25 times the maximum load under operating condition

29

- Weight of pipelines full of water (combined weight of pipe, insulation, valve

attachment etc. plus weight of water)

- Weight pipeline full of water as above plus any cold reaction as anticipated.

- Where the piping system is subjected to shock loads such as thrust imposed by the

actuation of safety valves, hanger design shall include provision of shock absorbing

devices of approved design. Vibration control devices shall be part of piping system

design.

- Outdoor piping shall be designed with due consideration to expansion resulting from

exposure to sunlight and care shall be taken to prevent progressive movement of long

pipelines. Outdoor piping may be supported on shoes, saddles or steel sections. Effect

of support friction especially for large dia pipelines shall be considered and friction

forces minimized by suitable arrangement. Piping inside the trenches shall be

supported at intervals on steel sections and the arrangement shall permit easy

maintenance.

09 Valves and specialties

- All valves shall be of approved make and type. All valves shall be suitable for service

condition i.e. flow, pressure and temperature under which they are required to

operate. The valves for high and medium steam service shall have butt welded ends

unless otherwise approved and the internal dia shall be same as that of the pipes to be

joined.

- All gate/ sluice, globe and needle valve shall be fitted with outside screwed spindles

and bolted type glands and covers. Spindle glands shall be of the bridge type

construction and screwed glands will not be accepted. All high pressure valves having

nominal dia more than 150mm, shall have integral steam bypasses concede to the

valve body by means of welded joints.

- All gate/sluice, globe and needle valve shall be provided with hand wheel and

position indicator. The face of each hand wheel shall be clearly marked with words

“open” and “shut” with arrows to indicate the direction of rotation to which each

refers. Arrangement limiting the travel of any valve in the “open” or “shut” position

shall be provided exterior to the valve body. All globe valves shall be designed to

prevent erosion of valve seats when the valves are operated partially opened. Valves

which cannot be operated from the floor or walkways, shall be provided with suitable

extension rods and linkages to facilitate operation from the floor or walkways. Chain

operation will not be accepted for steam valves. Stems shall preferably be arranged

vertically with gland at the top. In no circumstances must the gland be at the bottom.

Valves shall not be installed in an inverted position. The design of valves shall be

30

such that it will permit packing of glands under pressure. Where required, valve

spindles shall be extended so that the hand wheel is at a height of about 1.0m above

the level of the floor or platform from where the valves are to be operated. Where

required, they shall be provided with head stocks and pedestals of rigid construction

and where gears or bevel wheels are used, these shall be of cast steel or suitable grade

cast iron with machine cut teeth.

- Non return valves on all pumps discharges and steam line shall be of an approved non

slamming type. Draining arrangement shall be made on both sides of the horizontal

non-return valve where such a valve adjoins an isolating valve. Valve bodies shall be

provided with removable access cover to enable the internal parts to be examined

without removing the valves. Valves shall have a permanent “arrow” inscription on

its body to indicate direction of flow.

- Gate sluice valves for low pressure service shall be outside screw rising spindle type.

For these valves wherever necessary, chain operator shall be provided to operate the

valve from the floor or walkways. Larger size gate valves for low pressure

applications shall be provided with bypass and draining arrangement and valves with

dia more than 350mm shall be provided with gear operator. For low pressure water

applications, the non-return valves shall be lift check type for size upto DN 50mm

and swing check type for higher sizes.

- Valves in corrosive service shall be diaphragm or rubber lined type. Diaphragm shall

be of reinforced rubber and rubber lining of body shall have minimum thickness of

3mm. Generally plug valves shall be used in compressed air line. Plug valves shall be

supplied with wrench operator. Valves shall be of taper plug type. Sampling valves

for demineralised water shall be of cock type and stainless steel AISI 316.

- For motor operated valve, a 415V, 3 phase, 50Hz reversible speed motor shall be

furnished. Motor shall be capable of producing not less than 1.5 times the required

operator torque. Each operator shall be equipped with two adjustable limit and torque

switch for both open and closed position. The motor shall be of high torque low

starting current. Each operator shall be provided with auxiliary hand wheel for

manual operation. The hand wheel shall automatically disengage when the operator is

energized.

- Manual operator shall be of worm and gear type, having permanently lubricated,

totally enclosed gearing with hand wheel diameter and gear ratio designed to meet the

required operating torque. The operator shall be designed to hold the disc in any

intermediate position between full opened & full closed without creeping and

fluttering. Adjustable stop shall be built into the operator to prevent over travel in

31

either direction. Operator shall be equipped with direct coupled position indicator and

suitable locking device.

- Pressure reducing valves shall be perfectly stable, quiet and vibration less in

operation when reducing the pressure for any throughput upto maximum and shall be

suitable for continuous use at operating temperature. Valves shall be designed to

prevent erosion of the valve seats. Safety valves shall be the direct spring loaded type

and shall have a tight, positive and precision closing. All the safety valves shall be

provided with manual lifting lever. Valves used for compressible fluids shall be of

pop type. Safety valve shall be so constructed and adjusted to permit the fluid to

escape without increasing the pressure beyond 10% above the set blow off pressure.

Valve shall reset at a pressure not less than 2.5% and more than 5% the set pressure.

- The seat and disc of safety valves shall be of suitable material to resist erosion. The

seat of valves shall be fastened to the body of valve in such away that there is no

possibility of seat lifting.

09. Fabrication and installation of pipe work

- Pipe joints shall be assembled with the inside of all pipes and fittings smooth, clean

and free from burrs, scale, welding slag, sand and dirt. The inside edges of pipe and

tubing shall be reamed after cutting to remove burrs. Screw threads shall conform to

ANSI B 2.1 for taper pipe threads. All the threaded joints shall be made up with a

lubricant or compound suitable for the service under which the piping is to be used.

- Welded joints shall conform to “Code for pressure piping ANSI B31 1.0 (power

piping) or approved equivalent, except where the welding of such joints is covered by

other code requirements such as IBR, ASME pressure vessel and boiler code or

approved equivalent.

- Branches shall in generally be formed by welding standard fittings. Pipe bends and

tees shall be truly cylindrical and of uniform sections. Where permitted for certain

services, elbows or branch connections may be formed from steel pipe. Unless

otherwise agreed, slip-on welding flanges shall be used on pipe and for connection to

low pressure equipment. Welded neck flanges shall be used for butt welding fitting as

elbows, tees and reducers and for connection to high pressure equipment. Where class

125 ANSI flanges are bolted to 150 ANSI steel fittings, the 1.5mm raised face on the

steel flange shall be removed. When bolting such flanges, a full face gasket shall be

used. Equipment terminal flanges if consist of a different standard, a suitable

companion flange shall have to be provided at the connecting points.

32

- Flange drilling shall straddle the natural centre line of pipe. Faces of all flanges shall

be 900 to the longitudinal axis of the pipe to which they are attached. Slip-on flange

when used, shall be welded in accordance with ANSI B31.1 or any other equivalent

code. If distorted after welding, the flange shall be refaced. In all cases, flange faces,

must be free from particles of weld metal. The flange face and the pipe projecting end

shall then be machined to permit both pipe and flange to bear against.

11.All welding by the electric arc and gas welding process for pipe joints and fabrication

shall be done by qualified welders and done according to appropriate IBR, ANSI code

/ regulations as applicable for welding, subject to accompanying code regulations and

standards for filler metal, pressure, temperature and fluid carried. The ends of pipe

and welding fittings shall be beveled according to the details shown in ANSI B31.1 or

equivalent. All welds shall be made in such a manner that complete fusion and

penetration are obtained without an excessive amount of filler metal beyond the root

area. The reinforcement shall be applied in such a manner that it will have a smooth

contour merging gradually with the surface of adjacent pipe and welded fittings.

02.15 Thermal Insulation of Pipelines

Thermal insulation is applied to pipelines for two purpose.

i) To prevent heat loss to atmosphere in case of fluid being hot or to gain heat in

case of the fluid it contains is cold or below ambient temperature.

ii) To ensure that the skin temperature of the equipment or pipe is not more than

600C which is a permissible limit prescribed by the Inspector of factories.

Insulation Materials

Following insulating materials are normally used.

i) Unbonded mineral wool made from slag or rock confirming to IS : 3677 or glass

wool conforming to IS : 3690

ii) Bonded mineral wool conforming to IS:8183 made from slag or rock or glass

process from molten state into fibrous form and bonded with a suitable binder.

iii) Preformed fibrous pipe insulation conforming to IS:9842. The material shall be

mineral wool processed from rock or glass fibres.

33

iv) Insitu Polyurethane / polyisocynurate insulation conforming to IS:13205

(applicable for max operating temperature of 1100C).

Thickness of Insulation

Thickness of heat insulation to be provided is a function of the value of thermal

conductivity of the material selected, the temperature of the fluid and the bulk density of

the heat insulation material.

Following table gives the bulk density for unbonded and bonded mineral wool with

temperature limitations of hot face temperature.

Bonded Mineral Wool (kg/m3)

Pipe sections

Unbonded

Mineral wool Slabs /

mattresses Glass Wool Rock Wool

Max hot face

Temp 0C

120 kg/m3 50 85 120 250

150 kg/m3 80 85 120 400

200 kg/m3 120 85 120 550

34

Table for Insulation thickness

Pipe size

(outside dia) Insulation thickness in mm for various temperature ranges

Pipe size

(outside dia)

1000C

and

below

Between

101 and

2000C

Between

201 and

3000C

Between

301 and

4000C

Between

401 and

5000C

Above 5000C

Upto DN 50mm 25 50 50 75 100 100

DN 65 to DN

100mm

25 50 75 100 125 125

DN 125 &

DN 150mm

50 75 75 100 125 150

DN 200 mm 50 75 75 125 125 150

DN 250 mm 50 75 100 125 150 150

DN 300 mm 50 75 100 125 150 150

Note:

The metallic jacket over the insulation shall be galvanized steel sheet conforming to IS: 277

with following thicknesses:

- Pipe sizes up to 300 mm OD : 0.63 mm

- Pipe sizes up to 300 mm OD

equipment, flanges, valves : 0.80 mm

35

02.16 Load Calculations and Flexibility Analysis

02.16.01 Load Calculations

Loads from the piping system are transferred to the pipe supports and connected

equipment. Depending on the direction of application, loads are calculated under two

major heads :

• Vertical Loads

• Horizontal Loads

02.16.01.01 Vertical Loads

Vertical loads transferred to pipe supports comprise of the following :

• Dead weight of the pipes

• Weight of fluid in pipes

• Weight of insulation if any

• Condensate weight in gas pipeline

• Dust load due to deposition on pipeline

• Load due to mounted valves, compensator and fittings.

• Load due to saddles, supports and other service pipes

• Dead load and live load from Platforms and walkways

Empty weight of pipes shall be taken from standard weight tables.

In case of pipes carrying liquid, fluid weight with full pipe section shall be considered.

Following norms shall be followed for calculating the condensate load in low pressure

fuel gas mains.

Pipe dia. (mm) Height of filling of pipe cross-

section with condensate (mm)

Filling in cross-

section (%)

1. Upto DN 500

2. DN 600 – DN 1400

3. DN 1500 – DN 3500

Full

500

500 – 800

100

88 – 35

30 – 14

36

Load due to dust deposition shall be as follows:

• 50 Kg/m2 on pipelines at a distance within 100 m from dust generating plant (viz.

Blast Furnace, Coke ovens, SMS, Lime and Dolomite plant etc.)

• 25 Kg/m2 on pipelines at a distance between 100 m to 500 m from dust generating

plants.

Weight of valves, compensators and other mounted accessories shall be taken from

drawings/ catalogues.

Live load on platform shall be taken as 500 Kg/m2. This is indicated to Structural Section

for designing platforms.

It is recommended to add 10% to 20 % of vertical load as a provision for pipes to be laid

in future on the same route.

02.16.01.02 Horizontal loads

Horizontal loads transferred to pipe supports comprise of the following:

• Load due to thermal expansion

• Load due to internal gas pressure i.e. blanking load, load due to annular space of

compensator, unbalanced pressure load at branch locations, etc

• Load due to friction

• Wind load

Depending on the pipe configuration, horizontal loads can be in axial direction as well as

in transverse direction.

Horizontal loads due to thermal expansion, internal pressure and friction are calculated

by carrying out flexibility analysis on individual pipe. Procedure is given in para 05.03.

However, wherever possible, standard software package like CEASER-II may be used

for carrying out flexibility analysis and calculations of loads transmitted to supports and

nozzles of equipment to which piping is connected.

02.16.02 Location of Pipe Supports

Supports for pipes shall be provided based on pipe layout. Span between two consecutive

supports for a pipe shall be limited to the values given in Table 05.01 and 05.02

37

In specific cases where span between two supports can not be provided as per the table,

alternative arrangement for intermediate support using bridge between trestles or guy

rope supports may be considered. In exceptional cases where distance exceeds the

limiting span, suitable stiffening of pipe section to prevent sagging may be considered.

At sliding supports pipe saddle shall be allowed to rest on bearing plate for free

movement. In case U-clamps are provided, clearance shall be maintained for pipe

movement by providing two nuts on opposite sides.

All intermediate supports shall be of sliding type. Anchor supports shall be located based

on piping configuration and layout to provide adequate flexibility.

Distance between two consecutive fixed supports in straight runs of pipe route should be

approx 70 m. However, in special cases it may go up-to 100 m (max.). In no case it

should exceed 100 m.

However, for steam pipeline it should be limited to 60 m. For pipe dia. above 100 mm

cold pull if any during erection may be given as per instructions of the respective

drawings.

To reduce friction force transmitted to supports, roller supports or anti friction pad

supports can also be used.

05.03 Flexibility Analysis

Piping arrangement shall provide for flexibility of lines to take care of the thermal

expansion, contraction and equipment settlement. Large reactions or moments at

equipment connections shall be avoided . Expansion computation shall be made on the

basis of a base temperature of 21.1deg C (70 deg F) and shall cover ( +ve, or –ve ) design

temperature(s) as given.

i) Flexibility analysis shall meet the requirement of Code ASME B-31.3 (Latest

Edition). Analysis shall consider stress intensification factors as per ASME

B31.3.

ii) Lines which shall be subjected to steam out conditions , shall be designed and

analyzed at low –pressure steam design temperature of line whichever is more.

Lines having negative design temperature shall be analyzed for both conditions

separately.

38

iii) Flexibility Analysis of lines shall be carried out using simplified methods or a

comprenhensive computer program. Comprehensive computer analysis shall be

carried out for the piping as per Cl. No. 05.03 (vii) For lines connected to

equipment like vessels, pumps, filters, furnace, compressors or other strain

sensitive equipment. The result of the analysis must satisfy the allowable loading

on the nozzles of such equipment.

iv) Piping shall be adequately supported for the weight of piping, water, attached

unsupported components, wind, seismic, insulation and any other applicable

forces. Care should be taken that these supports are adequate to prevent excessive

stress, load or moments in either the piping or terminal nozzles of the equipment

to which it is connected. Adequacy of supporting of lines having heavy valves

shall be checked. The support shall be indicated in the piping General

Arrangement Drawings and Isometrics as applicable.

v) Safety valve manifolds and downstream of control valves shall be adequately

supported to avoid vibrations.

vi) The following factors shall be considered in the stress analysis

- Friction for lines >= 8” NB ; @ steel to steel = 0.3: ( Sliding friction), @

steel to Steel =0.1 (Rolling friction),

- Corrosion Allowance.

- Initial displacement of nozzles at design temperature(s).

- Transverse deflections =25 mm( maximum)

- Longitudinal expansion/contraction = 200 mm (maximum) Special care to

be taken to check for expansion loops and shoe support lengths shall be

finalized accordingly.

viii) The following shall always be analyzed using comprehensive computer

analysis:

a) All lines 4” and above and Design Temp.> 300 deg. C.

b) All lines 8” and above and Design Temp. > 150 deg. C.

c) Al l lines 16” and above and Design Temp. > 80 deg. C.

d) All lines 6” and above and Design Temp. > deg. 65 C that are connected

to rotating Equipment, Air Coolers or any other sensitive equipment.

e) Any other system/line that stress engineer feels necessary for stress check.

The report shall comprise of the following:

- Basic input data and calculated conditions.

39

- Layout isometric and supports configuration.

- Load cases and calculated member stresses.

- Forces, moments and displacements reports.

- Spring hangers design parameters.

- Allowable Stress Range.

Additional requirements ( reinforcement pad etc.)

02.16.04 Wind Load Calculation

Wind load acts on transverse direction across pipe due to pressure of wind.

Wind pressure shall be taken as per IS : 875. In cyclone prone areas maximum wind

pressure due to cyclonic wind pressure shall be taken.

Wind load for a section of pipe = Wind pressure X projected area x shape factor

For circular pipes shape factor is 0.7.

In case of multiple pipes, for each tier of pipes, largest pipe may be considered for

calculating wind load.

02.17 Piping Material Specification

02.17.01 Scope

This PMS covers the various piping specification for process and utility piping in

Metallurgical plants and its related industrial Installation.

Deviation from this specification may be necessary to conform to specific job

requirements. In such cases a separate and specific PMS shall be issued with the approval

of piping competent authority.

02.17.02 Referred Codes & Standards

All piping shall be designed in accordance with relevant latest codes and standards like B

31.1, B 31.3 and different IPSS (Inter plant standard for steel industry)

Individual piping material specification has been designed to cover a set of services

operating within fixed pressure and temperature.

40

02.17.03 Pipes

Pipe dimension shall be in accordance with ANSI B36.10 : IS:1239, IS:3589 for carbon

steel pipe and to B36.10/B36.19 for stainless steel pipe.

Pipe made by acid Bessemer process shall not be acceptable.Pipes shall be made by open

hearth, electric furnace or basic oxygen process.

All pipe threads shall conform to ANSI B1.20.1 except where otherwise noted.

02.17.04 Flanges

Flanges shall be in accordance with following codes except where otherwise noted.

DN 15 to DN 600 (150 # - 600#) ANSI/ANSI B16.5 / IS : 6392

Above DN 600API 605/ANSI B16.47/MSS-SP-44/

IS:6392 DIN etc.

Flanges to MSS-SP-44 or any other std. like DIN, BS etc. may be specified to be made

with equipment or valve flanges with corresponding bolting.

Finish of steel flange faces shall conform to MSS-SP-6/ ASME B46.1/ASME B16.5. The

interpretation shall be as follows :

Serrated : 250 – 500 Mu in AARH

Smooth (125 AARH) : 125 – 250 Mu in AARH

For RTJ groves (32 AARH) : 32 – 250 Mu in AARH

Bore of WN flanges shall match the ID of the attached pipe Bore of slip on flanges shall

suit the pipe OD and its thickness.

Dimensions of welded steel flanges for low pressure gas ( Pressure upto 1 kg/cm2) is

indicated in Table 06.01

02.17.05 Fittings

Forged steel socket welded and threaded fittings shall be in accordance with ANSI B

16.11 unless otherwise noted.

41

Butt welded fittings shall be in accordance with ANSI B16.9 unless otherwise noted.

Fabricated (site/factory) fittings shall conform to IPSS-06-020-95 unless otherwise

specified.

Fittings thickness and tolerance shall match pipe thickness and tolerance.

Mitres and reducers fabricated form pipe may be use if specified in PMS, shall conform

to IPSS:1-06-020-95. In no case mitres thickness and material shall be inferior to parent

pipe.

02.17.06 Gaskets

Non metallic gasket shall conform to IS:2712.

Spiral wound gaskets (SPR, WND) shall conform to API 601/B16.20.

Ring type and spiral wound gasket shall be self aligning type.

02.17.07 Bolting

Dimensional std of Bolt/studs and nuts shall conform to B 18.2 / IS:1364-1992. Unless

otherwise noted.

02.17.08 Threads

Threads for threaded pipes, fitting flanges and valves shall be in accordance with B1.20.1

taper threads unless otherwise noted.

Upto 2000C threaded joints shall be made with 1” width PTEE joining tape.

Above 2000C threaded joints shall be seal welded with full strength fillet weld.

All threaded joints irrespective of pressure and temperature on lines carrying toxic fluid

shall be seal welded with a full strength fillet weld.

42

02.18 Valves

02.18.01 Face to Face/End to End dimension of valves shall conform to B16.10 to the extent

covered. For valves not covered in B16.10. reference shall be made to BS2080 and / or

the manufacturer’s drawings.

02.18.02 Flange / weld ends of the valve shall be as per the corresponding Flange/Fitting ends of

the piping class, unless otherwise specified.

02.18.03 Pressure temperature rating for flanges and butt welding end valves shall be as per ANSI

B16.34 except for ball, plug & butterfly valves. For these valves refer TABLE FOR

PRESSURE TEMP. RATING FOR BALL, PLUG AND BUTTERFLY VALVES

02.18.04 Unless called-out specifically, valves shall be as per the following Standards.

Valve Size DN

mm

Rating Des. Std. Testing Std.

Gate 15 - 40 800/1500 API-602 API-598

Globe/Check 15 - 40 800/1500 BS – 5352 BS-6755 Pt-I

Gate 50 - 600 150/300/600 API-600 API-598

Gate 650 - 1050 150/300 BS-1414 BS-6755 Pt-I

Globe 50 – 200 150/300/600 BS-1873 BS-6755 Pt-I

Check 50 – 600 150/300/600 BS-1868 BS-6755 Pt-I

Gate/Globe/Check 900/1500/2500# B-16.34 API-598/

BS6755 Pt-I

Ball 15 – 400 BS-5351 BS-6755

Plug 15 – 300 API-599 API-598 /BS-

5353 BS-

6755

Butterfly 80 &

above

- API-609/

BS5155

AWWA C504

API-1898/ BS-

6755 Pt-I

/AWWA

Diaphram ALL - BS-5156 BS-6755 Pt-I

43

02.18.05 If not covered in 06.09.04 the valve shall be as per B16.34 and relevant MSS SP Standard

02.18.06 DN 50mm and larger steel Gate, Globe & Check valves in Hydrocarbon and utility

service shall have bolted bonnets. Pressure seal bonnets or covers shall be used for

Classes 900# and above to minimize bonnet leakage. However, valves with pressure seal

bonnet shall have wall thickness & seal stem diameter as per API600. Welded bonnets or

screwed & seal welded bonnets are acceptable for sizes lower than DN 50 for Classes

900# & above.

44

02.19. PIPING MATERIAL SPECIFICATION

02.19.01 Service : BF Gas, CO Gas, BOF, Corex Gas & Mixed Gas

Service Conditions : Maximum Working Pressure 1500mmWC Temp 60

oC

Minimum Working Pressure 50 mmWC Temp 5 oC

Corrosion Allowance: 2 mm.

Item Size Range Description Dimension

Standard

Material

Specification

DN 15 to 40 ERW, PE; Sch Heavy IS : 1239 IS:1239 - Black

DN 50 to 150 ERW, BE; Sch Heavy IS : 1239 IS:1239 - Black

DN 200 to

350

ERW, BE; 6 mm Thk IS : 3589 IS: 3589 Gr.330

DN 400 to

750

ERW/SWP,BE; 8 mm Thk IS : 3589 IS: 3589 Gr.330

Pipe

DN 800 to

3500

Fabricated – Electric Fusion

Welded, BE;10mm Thk.

IS : 3589 IS : 2062, Gr.B

DN 15 to 40 SW /Screwed Fittings

(Elbow R=1.5D)

IS : 1239

(P-2)

IS : 1239 (P-2) Black

DN 50 to 150 BW (Elbow R=1.5D) IS : 1239

(P-2)

IS : 1239 (P-2) Black

Fittings

DN 200 &

above

Fabricated Miters bends &

fittings from pipe / plate

IPSS-06-20 IS : 2062, Gr.B

Upto DN 150

SORF; Serrated Finish IS : 6392

Table - 5

IS: 2062, Gr.B

DN 200 to

300

SORF; Serrated Finish IPSS:1-06-20

Table 3

IS: 2062, Gr.B

Flanges

#150

DN 400 &

above

SORF; Serrated Finish IPSS:1-06-20

Table 3

IS: 2062, Gr.B

Upto DN 500 Gasket: Thk. 2 mm Ring

Type CAF

As per Flange IS : 2712 Gr W/3 Gaskets

Above DN

500

Asbestos rope graphite

impingnated. Ǿ8mm

Valves

DN 15 to 40 Gate valve; Screwed API 602 Body ASTM A105;

Cr 13% Trim

45

Item Size Range Description Dimension

Standard

Material

Specification

DN 50 to 550

Gate valve; Flanged IS : 14846 Body CI GR. FG 200

DN 600 to

1600

Gate valve; Flanged IPSS: 1-06-

023

Body CI, Gr.FG-210

DN 1800 &

above

Gate valve; Flanged MSS Body IS: 2062 GR. B

DN 15 to 40 Check valve SW – Lift

Type #800

BS 5352 Body A105, 13% CR

Trim

DN 50 and

above

Check Valve Flanged swing

check valve/ dual plate #150

BS 1868 /

API 594

Body A216;WCB,

13% CR Trim

DN 15 to 40 Globe valve SW / Screwed ;

#800

BS 5352 Body A105, 13% CR

Trim

DN 50 to 300 Globe valve; Flanged ;

Serrated Finish; #150

BS 1873 Body A216 Gr WCB,

13% CR Trim

DN 350 &

above

Butterfly valve WAF Type;

#150

BS 5155/ API

594

Body A216 Gr

WCB;13% Cr Trim

DN 15 / DN

25

LUB.TAPER

ED PLUG

VALVE

Screwed BS: 5158 Body & PLUG : CI

IS 210 FG 200

M/C Bolts IS: 1364-1992 ASTM A193 Gr B7

Bolting

All

Nuts IS: 1364- 992 ASTM A194 Gr 2H

Piping

Fabrication

Flanged

Joints

At valve/ equipment location and for sectionalising & Maintenance.

To be kept minimum

DN 50 & below SW coupling Pipes Joints

DN 50 & above Butt welded

Fabricated

pipes

Fillet welding using semi bandage on each segment.

Temp

Connections

DN 40 – Flanged set-on nozzle

Pressure

Tapping

DN 20 – SW Half Coupling Nipple Sch 80 with Gate valve to Spec.

Vents On lines >= DN 50 ; MEC std.

Drains On lines >= DN 80, MEC Std.

46

02.19.02 PIPING MATERIAL SPECIFICATION

Service: LPG

Service Conditions : Maximum Operating Pressure 6 kgf /cm2 Temp 60 oC

Minimum Operating Pressure Atm Temp 5 oC

CORROSION ALLOWANCE : 1.5 mm.

Item Size Range Description Dimensional/

Design

Standard

Material -

Carbon Steel

DN 15 to 40 Seamless PE Sch. 80 B 36.10 API 5L GR.B

DN 50 to 150 Seamless BE Sch.40 B36.10 API 5L GR.B

DN 200 to

300

Seamless BE Sch.20 B36.10 API 5L GR.B

DN 350 Seamless BE Sch.10 B36.10 API 5L GR.B

Pipe

DN 16 &

above

EFSW BE Thk. 6.0mm B36.10 API 5L GR.B

DN 15 to 40 SW / Screwed Fittings

# 3000 (Elbow R=1.5D)

ANSI B 16.11 ASTM A 105

DN 50 to 150 BW Fittings #150

(Elbow R=1.5D)

ANSI B16.9 ASTM A234 Gr WPB

Fittings

DN 200 &

above

Miter bends & fittings

fabricated from pipe

IPSS-1-06-020 Same as parent pipe

DN 15 to 40

SW:RF : Serrated Finish;

#150

B 16.5 ASTM A 105 Flanges

DN 50 &

above

SORF : Serrated Finish;

#150

B 16.5 ASTM A 105

Gaskets All sizes Gasket : Thk. 2.0 mm

Ring type CAF

B 16.21 IS : 2712 Gr W/3

DN 15 to 40 Gate valve SW # 800 API 602 Body A105 ; 13% CR

Trim

DN 50 to

600

Gate valve Flanged RF

Serrated Finish # 150

API 600 Body A216 Gr. WCB

13% Cr Trim

DN 15 to 40 Globe valve, SW # 800 BS 5352 Body A105; 13% Cr

Trim

Valves

DN 50 to 200 Globe valve : Flanged

RF Serrated # 150 finish

BS 1873 Body A216 Gr.WCB

13% Cr Trim

47

Item Size Range Description Dimensional/

Design

Standard

Material -

Carbon Steel

DN 15 to 40 Check valve SW # 800

Lift type

BS 5352 Body A105; 13% Cr

Trim

DN 50 to

600

Check valve flanged RF

Serrated finish # 150

BS 1868 Body A216 Gr.WCB

13% Cr Trim

DN 15 to 150 Ball valve flanged RF

Serrated finish #150

BS 5351 Body A216 Gr.WCB

13% Cr. Trim

Studs / Bolts B 18.2 ASTM A193 Gr B7 Bolting

All

Nuts B 18.2 ASTM A194 Gr 2H

DN 15 to 40 TRAP #150,

THRMDNMC

MANF’ STD. BODY A105, TRIM

13% CR , S: SS304

DN 15 to 40 PERM. STR, SW, Y

Type

MANF’ STD. BODY A05: INT SS

304

DN 50 to 350 PERM. STR, BW, T

Type

MANF’ STD. BODY A234WPB :

INT SS 304

DN 400 to

600

PERM. STR, BW, T

Type

MANF’ STD. BODY A234WPBW:

INT SS 304

Miscellaneous

Above DN

600

TEMP. STR, FF, CONE

Type

MEC’ STD. BODY A516GR. 70:

INT SS 304

Flanged

Joints

At valve/ equipment location and for sectionalizing & maintenance

To be kept minimum

DN 40 & below SW coupling

Piping

Fabrication

Pipes

Joints DN 50 & above Butt welded

Pressure

Tapping

DN 20 – SW half coupling Nipple Sch 80 with Gate valve to spec.

Gate

Temp

Connections

DN 40 – Flanged set-on nozzle

Vents On lines <= DN 40 ; MEC std.

Drains On lines <= DN 40 ; MEC std.

48

02.19.03 Service: Medium Pressure Nitrogen , Argon, & Compressed Air.

Service Conditions: Maximum Operating Pressure 10.5 kgf /cm2 Temp 60

oC

Minimum Operating Pressure Atm Temp 5 oC

Corrosion Allowance: 1.5 m.m.

Item Size Range Description Dimensional/

Design

Standard

Material -

Carbon Steel

DN 15 to 40 ERW, PE Sch. HEAVY IS:1239 IS:1239

BLACK

DN 50 to 150 ERW, BE Sch. HEAVY IS:1239 IS:1239 BLACK

DN 200 to

350

ERW, BE , THK 6.0mm IS:3589 IS:3589 GR.330

DN 400 to

500

ERW, BE , THK 8.0mm IS:3589 IS:3589 GR.330

DN 550 to

600

ERW BE Thk. 10.0mm IS:3589 IS:3589 GR.330

Pipe

DN 650 &

above

ERW/ SAW, BE Thk.

10.0mm (min)

IS:3589 IS:3589 GR.330

DN 15 to 40 SW / Screwed Fittings

# 3000 (Elbow R=1.5D)

ANSI B 16.11 ASTM A 105

DN 50 to 150 BW Fittings #150

(Elbow R=1.5D))

ANSI B16.9 ASTM A234 Gr WPB

Fittings

DN 200 &

above

Miter bends & fittings

fabricated from pipe

IPSS-1-06-020 Same as parent pipe

DN 15 to 40

SW:RF : Serrated Finish

#150

B 16.5 ASTM A 105

DN 50 to 600 SORF : Serrated Finish

#150

B 16.5 ASTM A 105

Flanges

DN 650 &

Above

SORF : Serrated Finish

#150

B 16.47 /

IS:6392 / API

605

ASTM A 105

Gaskets All sizes Gasket : Thk. 2.0 mm

Ring type CAF

B 16.21 IS : 2712 Gr W/3

Valves

DN 15 to 40 Gate valve SW # 800 API 602 Body A105 ; 13% CR

Trim

49

Item Size Range Description Dimensional/

Design

Standard

Material -

Carbon Steel

DN 50 to

600

Gate valve Flanged RF

Serrated Finish # 150

API 600 Body A216 Gr. WCB

13% Cr Trim

DN 15 to 40 Globe valve, SW # 800 BS 5352 Body A105; 13% Cr

Trim

DN 50 to 200 Globe valve : Flanged

RF Serrated # 150 finish

BS 1873 Body A216 Gr.WCB

13% Cr Trim

DN 15 to 40 Check valve SW # 800

Lift type

BS 5352 Body A105; 13% Cr

Trim

DN 50 to

600

Check valve flanged RF

Serrated finish # 150

BS 1868 Body A216 Gr.WCB

13% Cr Trim

Bolting

All Studs / Bolts

Nuts

B 18.2

B 18.2

ASTM A307 Gr B

ASTM A563Gr B

DN 15 to 40 TRAP #150,

THRMDNMC

MANF’ STD. BODY A105, TRIM

13% CR , S: SS304

DN 15 to 40 PERM. STR, SW, Y

Type

MANF’ STD. BODY A05: INT SS

304

DN 50 to 350 PERM. STR, BW, T

Type

MANF’ STD. BODY A234WPB :

INT SS 304

DN 400 to

600

PERM. STR, BW, T

Type

MANF’ STD. BODY A234WPBW:

INT SS 304

Miscellaneous

Above DN

600

TEMP. STR, FF, CONE

Type

MEC’ STD. BODY A516GR. 70:

INT SS 304

Flanged

Joints

At valve/ equipment location and for sectionalizing & maintenance

To be kept minimum

DN 40 & below SW coupling

Piping

Fabrication

Pipes

Joints DN 50 & above Butt welded

Pressure

Tapping

DN 20 – SW half coupling Sch 80 Nipple with Gate valve to spec.

Temp

Connections

DN 40 – Flanged set-on nozzle

Vents On lines <= DN 40 ; MEC std.

Drains On lines <= DN 40 ; MEC std.

50

02.19.04 Service: High Pressure Nitrogen, Argon & Compressed Air

Service Conditions: Maximum Operating Pressure 40 kgf /cm2 Temp 60

oC

Minimum Operating Pressure 10.5 kgf /cm2 Temp 5 oC

Corrosion Allowance: 1.5 mm.

Item Size Range Description Dimensional/

Design

Standard

Material - Carbon

Steel

DN 15 to 40 Seamless PE Sch. 80 B 36.10 ASTM A106

Gr.B

DN 50 to 150 Seamless BE Sch.40 B36.10 ASTM A106

Gr.B

DN 200 to

250

Seamless BE Sch.30 B36.10 ASTM A106

Gr.B

DN 300 to

350

Seamless BE Sch. Std. B36.10 ASTM A106

Gr.B

Pipe

DN 400 to

600

EFSW BE Thk.

Calculate

B36.10 ASTM A672 B60 CL 12

DN 15 to 40 SW Fittings

# 3000 (Elbow R = 1.5D)

ANSI B

16.11

ASTM A 105

DN 50 to 350 BW Fittings

(Elbow R = 1.5D)

ANSI B16.9 ASTM A234 Gr WPB

Fittings

DN 400 to

600

BW Fittings

(Elbow R = 1.5D)

ANSI B16.9 ASTM A234 Gr WPBW

DN 15 to 40

SW:RF : Serrated Finish

#300

B 16.5 ASTM A 105 Flanges

DN 15 to 600 WNRF : Serrated Finish

#300

B 16.5 ASTM A 105

Gaskets All sizes SPIRAL; THK. 4.4 mm API 601 SS 304 SPR. WND + CA

FIL

DN 15 to 40 Gate valve SW # 800 API 602 Body A105 ; 13% CR

Trim

Valves

DN 50 to 600 Gate valve Flanged RF

Serrated Finish # 300

API 600 Body A216 Gr. WCB 13%

Cr Trim

51

Item Size Range Description Dimensional/

Design

Standard

Material - Carbon

Steel

DN 15 to 40 Globe valve, SW # 800 BS 5352 Body A105; 13% Cr Trim

DN 50 to 200 Globe valve : Flanged RF

Serrated # 300 finish

BS 1873 Body A216 Gr.WCB 13%

Cr Trim

DN 15 to 40 Check valve SW # 800 lift

type

BS 5352 Body A105; 13% Cr Trim

DN 50 to 600 Check valve flanged RF

Serrated finish # 300

BS 1868 Body A216 Gr.WCB 13%

Cr Trim

DN 15 to 150 Ball valve flanges RF

Serrated finish # 300

BS 5351 Body A216 Gr.WCB 13%

Cr. Trim

DN 15 to 300

Plug valve flanges RF

Serrated finish # 300

BS 5353

Body A216 Gr.WCB

HARDEN PLUG

Bolting

All Studs /Bolts

Nuts

B 18.2

B 18.2

ASTM A193 Gr B7

ASTM A194 Gr 2H

DN 15 to 40 TRAP #150,

THRMDNMC

MANF’ STD. BODY A105, TRIM 13%

CR , S: SS304

DN 15 to 40 PERM. STR, SW, Y Type MANF’ STD. BODY A05: INT SS 304

DN 50 to 350 PERM. STR, BW, T

Type

MANF’ STD. BODY A234WPB : INT

SS 304

DN 400 to

600

PERM. STR, BW, T Type MANF’ STD. BODY A234WPBW: INT

SS 304

Miscellaneous

DN to 600 TEMP. STR, FF, CONE

Type

MEC’ STD. BODY A516GR. 70: INT

SS 304

Flanged

Joints

At valve/ equipment location and for sectionalizing & maintenance

To be kept minimum

DN 40 & below SW coupling

Piping

Fabrication

Pipes

Joints DN 50 & above Butt welded

Pressure

Tapping

DN 20 – SW half coupling Nipple Sch 80 with Gate valve to spec.

Temp

Connections

DN 40 – Flanged set-on nozzle

Vents On lines <= DN 40 ; MEC std.

Drains On lines <= DN 40 ; MEC std.

52

02.19.05 Service: Instrument Air (UP TO 1.5”)

Service Conditions: Maximum Operating Pressure Up to 10.55 kgf /cm2 Temp 65

oC

RATING: # 150

Matching Companion Flanges of Valves & flow components as per corresponding

rating.

Corrosion Allowance: NIL

Item Size Range Description Dimensional/

Design

Standard

Material -

Carbon Steel

Pipe DN 15 to 40 ERW ; Screwed end

HEAVY

IS:1239 IS:1239

(PART-I)

GALV.

Fittings

DN 15 to 40 Screwed Fittings

# 3000

ANSI B 16.11 ASTM A 105

(GALV.)

DN 15 to 40

Screwed :RF : Serrated

Finish #150

B 16.5 ASTM A 105

(GALV.)

DN 15 to 40

Blind Flanged RF :

Serrated Finish #150

API 590 ASTM A 105

(GALV.)

Flanges

DN 15 to 40

FIG. 8 Flange ; FF

Serrated Finish #150

B 16.5 ASTM A 105

(GALV.)

Gaskets All sizes Gasket : Thk. 2.0 mm

Ring type

B 16.21 IS : 2712 Gr W/3

DN 15 to 40 Gate valve SCRF; # 800 API 602 Body A105 ; 13% CR

Trim

DN 15 to 40 Globe valve, SCRF; #

800

BS 5352 Body A105; 13% Cr

Trim

Valves

DN 15 to 40 Check valve SCRF; #

800 Lift type

BS 5352 Body A105; 13% Cr

Trim

M/C BOLT B 18.2 ASTM A307 Gr B Bolting

All

Nuts B 18.2 ASTM A563 Gr B

Flanged Joints

53

Item Size Range Description Dimensional/

Design

Standard

Material -

Carbon Steel

Flanged Joints

Pipes

Joints

Screwed Coupling

Piping

Fabrication

Temp. Conn. Flanged Installation as MEC std.

Pressure

Tapping

DN 20 – SW half coupling Nipple HEAVY with Gate valve to spec.

Vents MEC std.

Drains MEC std.

54

02.19.06 Service: Low Pressure Steam, Condensate & Boiler Feed Water

Service Conditions: Maximum Operating Pressure 18 kgf /cm2 Temp 360

oC

Corrosion Allowance: 1.5 m.m.

Item Size Range Description Dimensional/

Design

Standard

Material -

Carbon Steel

DN 15 to 40 Seamless PE Sch. 80 B 36.10 ASTM 106

GR.B

DN 50 to 150 Seamless BE Sch.40 B36.10 ASTM106 GR.B

DN 200 to

300

Seamless BE Sch.40 B36.10 ASTM106 GR.B

Pipe

DN 350 to

400

Seamless BE Sch.40 B36.10 ASTM106 GR.B

DN 15 to 40 SW Fittings

# 3000; (Elbow R=1.5D)

ANSI B 16.11 ASTM A 105

DN 50 to 600 BW Fittings

(Elbow R=1.5D)

ANSI B16.9 ASTM A234 Gr WPB

Fittings

DN 200 to

600

BW Fittings

(Elbow R=1.5D)

ANSI B16.9 ASTM A234 Gr

WPBW

DN 15 to 40

SW:RF : Serrated Finish B 16.5 ASTM A 105 Flanges

DN 50 to 600 WNRF : Serrated Finish B 16.5 ASTM A 105

Gaskets All sizes Gasket : Thk. 2.0 mm

Ring type CAF

B 16.21 IS : 2712 Gr W/1

DN 15 to 40 Gate valve SW # 800 API 602 Body A105 ; 13% CR

Trim

DN 50 to

400

Gate valve Flanged RF

Serrated Finish # 300

API 600 Body A216 Gr. WCB

13% Cr Trim

DN 15 to 40 Globe valve, SW # 800 BS 5352 Body A105; 13% Cr

Trim

DN 50 to 200 Globe valve : Flanged

RF Serrated # 300 finish

BS 1873 Body A216 Gr.WCB

13% Cr Trim

DN 15 to 40 Check valve SW # 800

Lift type

BS 5352 Body A105; 13% Cr

Trim

Valves

DN 50 to

600

Check valve flanged RF

Serrated finish # 150

BS 1868 Body A216 Gr.WCB

13% Cr Trim

55

Item Size Range Description Dimensional/

Design

Standard

Material -

Carbon Steel

DN 15 to 150 Ball valve flanges RF

Serrated finish # 300

BS 5351 Body A216 Gr.WCB

13% Cr. Trim

Studs /Bolts B 18.2 ASTM A193 Gr B7 Bolting

All

Nuts B 18.2 ASTM A194 Gr 2H

DN 15 to 40 TRAP #300,

THRMDNMC

MANF’ STD. BODY A105, TRIM

13% CR , S: SS304

DN 15 to 40 PERM. STR, SW, Y

Type

MANF’ STD. BODY A05: INT SS

304

Miscellaneous

DN 50 to 400 PERM. STR, BW, T

Type

MANF’ STD. BODY A234WPB :

INT SS 304

Flanged

Joints

At valve/ equipment location and for sectionalizing & maintenance

to be kept minimum

DN 40 & below SW coupling

Piping

Fabrication

Pipes

Joints DN 50 & above Butt welded

Pressure

Tapping

DN 20 – SW half coupling Nipple Sch 80 with Gate valve to spec.

Temp

Connections

DN 40 – Flanged set-on nozzle

Vents On lines <= DN 40 ; MEC std.

Vents On lines >= DN 50 ; MEC std.

Drains On lines <= DN 40 ; MEC std.

Note:

1. Class of various items shall be selected based on the pressure of steam in the line ( For low

pressure inferior class may be considered)

2. For higher pressure i.e, more than 18 bar the technologist (PP & EE) to be contacted for

specification.

56

02.19.07 Service: Medium Pressure Oxygen

Service Conditions: Maximum Operating Pressure 15 kgf /cm2 Temp 60 oC

Corrosion Allowance: 2 m.m.

Cleaning, Pickling, Passivation & Degreasing As Per IGC: 33/86/E

Item Size Range Description Dimensional/

Design

Standard

Material -

Carbon Steel

DN 15 to 40 Seamless PE Sch. 80 B 36.10 ASTM A106

GR.B

DN 50 to 150 Seamless BE Sch.40 B36.10 ASTM A06 GR.B

DN 200 to 300 Seamless BE Sch.40 B36.10 ASTM A06 GR.B

Pipe

DN 350 to 600 Seamless BE Sch.40 B36.10 ASTM A06 GR.B

DN 50 to 150 Copper Pipe B36.10 Deoxidised non

Arsenic Copper

Fire

Breaker

DN 200 to 600 Copper Pipe B36.10 Deoxidised non

Arsenic Copper

DN 15 to 40 SW Fittings

# 3000; ( Elbow R=4D)

ANSI B 16.11 ASTM A 105 Fittings

DN 50 to 600 BW Fittings

( Elbow R=4D)

ANSI B16.9 ASTM A234 Gr WPB

DN 15 to 40

SW:RF : Serrated Finish B 16.5 ASTM A 105 Flanges

DN 50 to 600 WNRF : Serrated Finish B 16.5 ASTM A 105

Gaskets All sizes PTFE LOX GRADE B16.21 ASTM D3293; TYPE

3; Gr. 1+A

DN 15 to 40 Gate valve; SW; # 800 API 602 Body A182 GR. 304;

/BRONZE ;13% CR

Trim / BRONZE

DN 50 to 600 Gate valve; Flanged; RF;

Serrated Finish # 150

API 600 Body A351 GR.CF8

13% Cr Trim

Valves

DN 15 to 40 Globe valve, SW; # 800 BS 5352 Body A182 GR. 304;/

BRONZE; 13% CR

Trim/ BRASS

57

Item Size Range Description Dimensional/

Design

Standard

Material -

Carbon Steel

DN 50 to 200 Globe valve : Flanged

RF Serrated # 150 finish

BS 1873 Body Al BRONZE

CASTING; TRIM

BRASS; PTFE Seat

DN 15 to 40 Check valve SW # 800

lift type

BS 5352 Body A105; 13% Cr

Trim

DN 50 to 600 Check valve flanged RF

Serrated finish # 150

BS 1868 Body & Trim A182

GR. 304

DN 15 & Above Ball valve flanged RF

Serrated finish

BS 5351 Body A351 GR.CF8 ;

A182 GR. 304

Trim;PTFE Seat

Studs/Bolts B 18.2 ASTM A193 Gr B7 Bolting

All

Nuts B 18.2 ASTM A194 Gr 2H

Flanged Joints At valve/ equipment location and for sectionalizing & maintenance

To be kept minimum

DN 40 & below SW coupling

Piping

Fabrication

Pipes

Joints DN 50 & above Butt welded

Pressure

Tapping

DN 20 – SW half coupling Nipple Sch 80 with . Gate valve to spec.

Temp

Connections

DN 40 – Flanged set-on nozzle

Vents On lines <= DN 40 ; MEC std.

Vents On lines >= DN 50 ; MEC std.

Drains On lines <= DN 40 ; MEC std.

58

02.19.07 Service: High Pressure Oxygen

Service Conditions: Maximum Operating Pressure 40 kgf /cm2 Temp 60

oC

Minimum Operating Pressure 16 kgf /cm2 Temp 5 oC

RATING: # 300

Matching Companion Flanges of Valves & flow components as per corresponding

rating.

Corrosion Allowance: 2 mm.

Cleaning, Pickling, Passivation & Degreasing As Per IGC : 33/86/E

Item Size Range Description Dimensional/

Design

Standard

Material -

Carbon Steel

DN 15 to 40 Seamless PE Sch. 80 B 36.10 ASTM A106

GR.B

DN 50 to 150 Seamless BE Sch.40 B36.10 ASTM A06 GR.B

DN 200 to 300 Seamless BE Sch.20 B36.10 ASTM A06 GR.B

Pipe

DN 350 to 600 Seamless BE Sch.10 B36.10 ASTM A06 GR.B

DN 50 to 150 Copper Pipe B36.10 Deoxidised non

Arsenic Copper

Fire

Breaker

DN 200 to 600 Copper Pipe B36.10 Deoxidised non

Arsenic Copper

DN 15 to 40 SW Fittings

# 3000; ( Elbow R=4 D)

ANSI B 16.11 ASTM A 105 Fittings

DN 50 to 600 BW Fittings

( Elbow R=4 D)

ANSI B16.9 ASTM A234 Gr WPB

DN 15 to 40

SW:RF : Serrated Finish;

#300

B 16.5 ASTM A 105 Flanges

DN 50 to 600 WNRF : Serrated Finish

# 300

B 16.5 ASTM A 105

Gaskets All sizes CAF/ PTFE LOX

GRADE

B16.21 ASTM D3293; TYPE

3; Gr. 1+A

DN 15 to 40 Gate valve; SW; # 800 API 602 Body A182 GR. 304;

/BRONZE ;13% CR

Trim / BRONZE

Valves

DN 50 to 600 Gate valve; Flanged;

RF;Serrated Finish # 300

API 600 Body A351 GR.CF8

13% Cr Trim

59

Item Size Range Description Dimensional/

Design

Standard

Material -

Carbon Steel

DN 15 to 40 Globe valve, SW # 800 BS 5352 Body A182 GR. 304;/

BRONZE; 13% CR

Trim/ BRASS

DN 50 to 200 Globe valve : Flanged

RF Serrated finish; # 300

BS 1873 Body Al BRONZE

CASTING; TRIM

BRASS; PTFE Seat

DN 15 to 40 Check valve SW # 800

Lift type

BS 5352 Body A182 GR. 304;

/BRONZE ;13% CR

Trim / BRONZE

DN 50 to 600 Check valve flanged RF

Serrated finish # 300

BS 1868 Body A351 GR.CF8

13% Cr Trim

DN 15 & Above Ball valve flanges RF

Serrated finish #300

BS 5351 Body A351 GR.CF8 ;

A182 GR. 304

Trim;PTFE Seat

Studs B 18.2 ASTM A193 Gr B7 Bolting

All

Nuts B 18.2 ASTM A194 Gr 2H

Flanged Joints At valve/ equipment location and for sectionalizing & maintenance

To be kept minimum

DN 50 & below SW coupling

Piping

Fabrication

Pipes

Joints DN 50 & above Butt welded

Pressure

Tapping

DN 20 – SW half coupling Nipple Sch 80 with Gate valve to spec.

Temp

Connections

DN 40 – Flanged set-on nozzle

Vents On lines <= DN 40 ; MEC std.

Vents On lines >= DN 50 ; MEC std.

Drains On lines <= DN 40 ; MEC std.

Drains On lines <= DN 45 ; MEC std.

60

02.20 Erection

02.20.01 Fuel gas and oil pipelines

01 General

- All elements of the pipelines system shall be erected at site strictly as per the

drawings approved by the Purchaser/ Consultant.

- Any modification to be carried out at site, shall have the prior approval of

Purchaser/ Consultants representatives.

- While erecting, pipelines shall rest uniformly on each support. Yokes, if

provided, shall not allow lateral movement of pipes.

- Matching faces of flanges shall be perpendicular to the axis of pipelines. Use of

gaskets of unusual thickness to fill gap between flanges shall not be allowed.

- For horizontal pipes, the flanges shall bee erected such that top two bolt holes are

displaced by half pitch from the vertical axis of the flange.

- Flangers of adjoining pipes shall be located in staggered manner.

- Flanged joints shall be laid as close to the support as possible.

- In case the location of spindle wheel of valves is not clearly shown in the erection

drawings, the same shall be located in a manner as to facilitate easy operation

from ground level of nearest operating platform.

- For making pipe bends/ elbows at site using hot/ clod bending process, the

decrease in the pipe thickness shall not be more than 15% of the pipe thickness.

- After erection of pipelines, the holes made in the walls shall be covered with

bricks & mortar. A gap of 10 to 20 mm shall be kept between wall and the pipe

for the movement due to thermal expansion. The gap shall be filled with felt/

asbestos.

- Holes made in the roof shall be covered with removable CGI sheets.

- The trenches for pipes shall be covered with removable chequered plate covers/

concrete slabs as per the drawings.

- All pipeline branches not connected to equipment shall be closed using blank

flanges and gaskets.

61

02 Welding of pipelines

- All pipelines shall be joined by welding. Flanged joints shall be used for

connecting the pipe with equipment, valve or fitting.

- Electric arc welding shall be used for joining pipes, support, structures, etc.

- All manufactured pipes shall be joins by butt welding. Large dia pipes, fabricated

from sheets, shall be joined by fillet welding using semi- bandages attached each

section being joined.

- Welding shall be done by qualified welders. Code of practice as per relevant

Indian Standards shall be followed for the welding procedure, use of electrodes,

etc.

- Proper edge preparation and preheating of edges to be welded, whenever required,

shall be ensured before welding.

- After every 50 butt welded joints of gas pipeline, one test sample shall be welded

by the same welder. Tensile teat and bend test shall be performed as per IS :814 to

check the strength of welding. Four test samples shall be made from the test piece,

two each for tensile and bend test.

- Tensile strength shall not be less than 34 kg / mm2 and elongation less than 12 %.

- Angle of bend at the appearance of first crack shall not be less than 70 deg.

- Visual inspection shall be done for all welded joints to checks for following

possible defects.

- Surface cracks on weld metal or parents metal.

- Fusion or cuts at the joining of weld metal and parent metal.

- Sponginess or porosity on the surface of weld.

- Non-uniform thickness or distortion in case of fillet welds.

- Deviation in the pipe axes or dimension of the joint.

- All defective spots found shall be chipped off and re-welded.

- For high pressure pipes, radiographic examination of welds shall be

carried out as per IS : 2825.

03 Link lengths and tolerances

- Straight sections of gas pipelines shall be manufactured as separate links and

joined at site by butt welding.

- Link lengths for pipes shall be as follows :

a) Up to 13 m : for pipes with dia 1400 mm or less.

62

b) Up to 26 m : for pipes above 1400 mm dia.

- Following tolerances are allowed :

i) For length of links :

a) +/- 3 mm for length up 1 m

b) +/- 0.5 % for length more than 1 m, total deviation shall not exceed

10 mm for every 10 m or part thereof .

ii) Deviation in the pipe axis from the straight line :

Upto 0.12% of the link length but not more than 15mm for links with length more

than 10 m. Deviation shall be checked by stretched cord.

iii) For distance between the contracting surfaces from the geometrical axis for bends,

tees, crosses and other pipe fittings.

+/- 3 mm for distance upto 500 mm .

+/- 0.5% or 10 mm maximum for distance more than 1 m.

However, for BF gas and CO gas pipelines, the tolerance shall be limited to +/-

1.5 mm only.

iv) Deviation of pipe axes at the joining point from the diametral plane of pipes :

2 mm, irrespective of link length.

v) For distance between two adjacent connections on a pipe :

+/- 2 mm for each length but not more than +/- 5 mm overall.

vi) Distortion of the contacting surface of flange relative to the geometrical plane

perpendicular to the pipe axis :

0.004 times the outer diameter of the flange at the periphery.

vii) Tolerance for clearance between flanges and flange rings :

Not more than 2 mm.

04 Erection of valves and fittings

- Before erection, the valves, cocks and other fittings, to be mounted on pipelines,

shall be dismantled, cleaned, oiled and reassembled. Glands shall be packed with

suitable materials as per approved drawings.

- All moving parts of the pipe fittings should move freely without jamming.

- Valves shall be tested hydraulically for leakage by applying pressure on up stream

side with valve in closed position.

- Bolts & nuts shall be cleaned and lightly oiled.

63

- Proper grades of gaskets shall be used for erection as per approved drawings.

05 Testings of pipelines

- Preliminary acceptance test for erected pipelines shall be carried out as follows :

a) Checking of metal marked as per manufacturer’s certificate/ approved

drawings.

b) Checking of test result of mechanical tests for welding/ radiographic tests.

c) Visual examination of welds.

d) Dimensional checks as per the approved erection drawings.

e) Checking of welded joints by chalk kerosene test.

- In case defects are found by visual examination, these shall be rectified prior to

leakage test.

- Checking of proper installation of supports, expansion joints, valves and fittings.

- The pipeline shall be cleaned from inside, all debris removed and pipeline blown

with air to remove all dirt, rust particles, etc.

1) Strength and leakage test for low pressure gas pipelines :

a) Pipe sections shall be disconnected from equipment, etc. Using blank

flanges.

b) Test pressure equivalent to 1. 25 times the maximum operating pressure

but not less than 0.2 kg/ cm2 shall be applied using air.

c) Test pressure shall be maintained for 1 hour and then reduced to the

working pressure.

d) Soap solution shall be applied to the weld surfaces/ flanges to chaeck any

leakage.

e) Any defects found shall be rectified after releasing the pressure.

f) Tightness test shall be carried out by maintaining the test pressure

indicated in (b) above for a minimum period of 2 hours.

g) Pressure and temperature readings shall be taken at the beginning and end

of the test. The percentage pressure drop (P) shall be calculated as follows

:

P = 100 (1 – P2/ P1= * T1/ T2 )

Where P1 and P2 are pressure in the pipe at the beginning and end of test

and T1 and T2 are absolute temperatures at the beginning and end of the

tests.

64

h) For out door pipelines, the allowable pressure drops for different diameter

shall be as follows :

Upto 300 mm : 2.0%

300 to 1000 mm : 1.5%

Above 1000 mm : 1.0%

i) For indoor pipelines, the allowable pressure drop shall not exceed 1 %

2) High pressure pipelines ( above 1 kg/ cm2 g ) shall be tested as follows :

a) Pipe sections shall be disconnected from the equipment using blank

flanges.

b) Vents shall be provided at high points for air release during pipe filling.

The vents shall be plugged with threaded nipples after the tests.

c) Tests shall be carried out before painting of the pipelines and before

application of insulation.

d) Pipe upto 300 mm diameter shall be tested hydraulically for strength by

applying test pressure equivalent to 1.25 times the operating pressure. Test

pressure shall be maintained for 30 minutes and then gradually reduced to

the operating pressure. For steam pipelines test pressure shall be 1.5 times

the working pressure and duration 2 hrs.

e) Leakage from welded joints shall be checked by tapping with light

hammer. No sweating should occur on the weld surface. Test shall be

considered satisfactory if no visible leakage is found and pressure in

pipeline remains steady.

f) In case hydraulic testing is not feasible, test shall be carried out by

compressed air. Leakage from joints shall be checked by soap solution.

g) Test for tightness shall be carried out using compressed air at the operating

pressure, the test pressure shall be held for 12 hours. The percentage

pressure drop calculated as per formula given in para ( g ) of previous

clause shall not exceed.

06 Commissioning

- Pipelines shall be commissioned only after successful completion of acceptance

tests, strength tests and leakage tests.

- All valves and regulating devices shall be checked for proper operation.

- All safety relief valves shall be checked and set at required pressure setting.

- All instruments, interlocks, etc. shall be checked.

65

- Before charging the pipelines with fuel gas, the entire air from the pipeline shall

be purged with steam/ nitrogen.

- Before purging, all valves shall be set at required position, drain pots filled with

water, all hatches & manholes, closed. All bleeders except the ones used for

venting the purge gas shall be tightly shut.

- Discharged from the pipelines be through bleeder/ vents only. The air/ gas should

not discharge in to the shop/ furnace.

- After purging is complete, the fuel gas shall be gradually charged in to the

pipelines. The charging shall be done sectionwise gradually approaching the

consumer end.

- The gas shall be discharged through bleeders only. Exhaust gas from bleeders can

be set on fire.

- Completion of filling shall be determined by taking samples from the bleeders. In

case oxygen content of two successive samples is less than 1 % the gas blowing

shall be deemed to be complete.

- All activities of gas pipe purging and charging shall be co-ordinated with the

Energy Management Department of the plant. All safety regulations in force as

per practice followed by BSL shall be followed including presence of safety

personnel, fire engines, etc.

- After charging the gas into the system, all isolating devices, instrument, control,

safety devices, condensate seal pots, etc. Shall be again checked for proper

operation.

02.20.02 Oxygen pipelines

01 General

- All work concerning oxygen pipelines system shall be done by persons of

contractor well conversant with the oxygen service and having proven ability in

the field.

- All safety aspects with regards to selection of materials, erection procedure,

degreasing, testing and commissioning procedures, cleanliness, etc. shall be kept

in view by all personnel connected with the job.

- Erection of pipes, fittings, instruments, etc. shall be done strictly as per the

approved drawings. Any change proposed to be done at site shall have the

approval of the Purchaser’s/ Consultant’s representatives.

66

02 Routing of oxygen pipes

- Oxygen pipes can be laid along with other pipes on same stockades. Oxygen

pipeline shall have independent support from the same stockade.

- Clear distance of 300 mm shall be kept between oxygen pipe and any other pipe.

- In shop pipes can be laid along the wall and can be supported from building

structures, crane girders etc. by independent brackets, hangers, etc.

- Pipelines laid in trenches shall be covered with sand/ earth.

- Oxygen pipeline shall not be laid in tunnel/ basements. In case it is necessary to

pass the pipeline through a tunnel, an encasing pipe +shall be provided on oxygen

line extending 1.0 m on both ends of the tunnel.

- A clearance of 500 mm shall be kept between oxygen pipe and electrical cables

and in case of bare conductors, the clearance shall be 1000 mm.

- Oxygen pipelines crossing the walls/ floors shall also have encasing pipe. The gap

between the pipe and casing shall be filled with non-0inflamable material

allowing movement of the pipe.

- Oxygen pipelines shall be effectively earthed, Jumpers of minimum 5 mm

diameter shall be proved at all flanged joints.

03 Materials

- All materials supplied for erection shall have manufacturer’s test certificates

including materials test and hydraulic test reports.

04 Cleanliness

- All steel pipes & fittings shall be picked at the manufacture’s works or at site

prior to degreasing.

- In case the pickling is done at manufacturer’s work, the ends of pipes shall be

sealed/ plugged, and then pipes packed and tagged ‘picked for oxygen service’

before despatch.

- Pickling shall be done using HCL of 20% concentration (w/ w). After pickling,

pipes shall be washed with water, neutralised with 0.25% NaOH solution and

again washed with water.

- Before erection, the pipes & fittings shall be visually inspected for presence of

scales/ foreign matter like fillings, flux, corrosion products, dirt wood and metal

chips, threading compounds, sealants, tar asphalt, moisture, paint, chalk, etc.

- The pipe work shall be thoroughly cleaned to ensure removal of all foreign

matter.

67

- Presence of grease or oil shall also be checked visually. Inside surface of pipes

shall be checked by passing clean white cotton piece.

Hands, clothes and aprons of the workers doing erection job shall be clean and

free oil and grease.

05 Degreasing

- Before erection, all pipelines, fittings, valves, gaskets, packing material,

instruments etc. Shall be degreased using proper solvent like carbon tetrachloride

or trichloroethylene. For initial degreasing detergent made by mixture of sodium

hydroxide trisodium phosphate and calcium sodium silicate can be used.

- The quality of the solvent used for degreasing shall for degreasing shall be

checked before its application.

- The parts to be degreased should be cleaned and dried by blowing air.

- Outer surface of pipes is degreased by wiping with cloth dipped in solvent and

then dried till smell of solvent disappears.

- For degreasing inner surface of pipes, pipe shall be plugged at one end, filled with

solvent and closed at other end. Pipe shall be kept in horizontal position, rotated

about axis atleast once in a minutes. After continuing the process for about 15

minutes, the solvent shall be drained and pipe blown with dry oil free air or

nitrogen for at least 5 minutes.

- Drying after degreasing can also be done in open air for at least 24 hours.

- Vapour degreasing method can also be applied for pipes.

- For degreasing of valves, fittings and other components, the same shall be

dismantled and parts dipped in solvent for 5 to 10 minutes. After degreasing, the

parts shall be dried in open air till smell of solvent is eliminated.

- Gaskets and packing material shall be degreased by dipping in solvent for 1.5 to 2

hours after which these shall be dried in open air for 24 hours.

- Degreasing operation shall be done in open air.

- The workers should use safety masks to prevent hazards due to inhaling of the

solvent vapours. Solvent contact with skin shall also be avoided.

- Safety aspects regarding handling of solvents shall be kept in mind during

degreasing process.

006 Erection

- Erection of oxygen pipelines shall be done as per approved drawings and general

guidelines for erection of pipelines.

68

- Gas welding or electric arc welding shall be used for erection of pipelines.

Welding shall be done by qualified welders.

- Qualifying tests for welding, welding procedures and quality control etc. shall be

generally as per IS: 2825, ‘ code of Practice for Unifired pressure Vessels’.

- Radiographic examination of 100% welds for oxygen pipelines with working

pressure over 6 km/ cm2 and OD above 76 mm shall carried out. Interpretation of

radiographs shall be done by a competent agency like Lloyds Register of

Shipping. Proper identification marking for welds and their corresponding

radiographs shall be carried out by the contractor.

- For pipelines having working pressure below 6 kg/ cm2, 40% welds shall be

tested by radiography.

- Cleanliness of personnel as well as tools and tackles shall be ensured.

007 Testing

- All erected pipelines shall be tested for strength and leakage using dry and oil free

air or Nitrogen.

- Before testing, the pipeline shall be degreased by vapour degreasing method.

- After degreasing, the pipelines shall be blown with dry and oil free nitrogen.

During blowing, velocity in the pipelines shall not be less than 20 m/ sec.

- Blowing shall be done for a period of at least 1 hour to remove all particles of

dust, scale etc. from the system. Cleanliness shall be checked by holding a piece

of white paper at the air outlet.

- After blowing, the line shall be pressurized up to 1.25 times the maximum

working pressure of the pipeline using air/ nitrogen. The test pressure shall be

held for 30 minutes during which the joints shall be lightly tapped with a wooden

hammer of 1.5 kg weight.

- Pressure shall be gradually reduced to the operating pressure and all joints

checked by soap solution for leakage. If any leakage is detected, line shall be

depressurized and defect rectified.

- Leakage test for the pipeline system shall be done at operating pressure for a

period of 24 hours. During this period, pressure and temperature readings shall be

taken at an interval of 1 hour. Duplicate gauge with least count of 0.1 kg/ cm2 for

pressure and 0.5 deg. C for temperature shall be used.

- Leakage of air determined by formula indicated under clause 08.03.04.A. 005 (i)

9 shall not exceed 0.2% hour.

- After satisfactory completion of leakage test, the pipeline shall be isolated and

kept under pressure of 1.0 kg/ cm2 till the line is commissioned.

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008 Commissioning

- Before charging the pipeline with oxygen, the line shall be blown with dry, oil

free air/ nitrogen at a velocity of minimum 20 m/ s for a period of at least 8 hours.

Cleanliness of outlet air shall be checked by holding a piece of white paper for 3

to 5 minute at air outlet. If dust particles are found on the paper, blowing shall be

continued till paler test shown negative results.

- After completion of blowing, oxygen shall be introduced gradually increasing the

oxygen percentage in the pipe. The velocity of oxygen flow shall be limited to 10

m/ s till all air/ nitrogen is exhausted from the pipe.

- Oxygen shall be vented through bleeders on open atmosphere at a safe place away

from open flames/ fire. Minimum height of bleeders outlet shall be 2.5 m from

ground/ platform level or shop roof.

- After charging the line completely with oxygen, bleeder valves shall be closed

and line may be put into service.

009 Safety

- Testing, cleaning and commissioning of oxygen pipelines shall be carried out only

in the presence of and with the permission of senior engineers of the Purchaser

and the Contractor.

- The safety department of the Purchaser shall be informed and their concurrence

taken on all matters related to cleaning, testing and commissioning of oxygen pipe

lines.

- All first aid and fire fighting facilities should be readily available.

- During testing of pipelines by air, the area shall be cordoned off and clear

working placards shall be displayed.

- All safety precautions shall be observed in storage and handling of solvents.

02.21 Piping for Compressed Air, Steam, Condensate, Water, Feed Water & Slurry

02.21.01 Layout

⇒ Piping layout must follow good engineering practices. Proper attention shall be given

to obtain full functional requirement of piping system with a layout which provides

sufficient clearance for other equipment and operating personnel, easy access for

operation and maintenance, convenient supporting points, adequate flexibility for

thermal expansion movements and neat appearance. As far as practicable, interplant

pipelines shall be laid along X or Y axis of the plant grid system.

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02.21.02 Design Consideration

⇒ Piping system shall be designed with high degree of reliability so that the system

perform the duty of fluid handling without structural or functional failure under most

adverse conditions of plant operation anticipated. All piping system shall be designed

with sufficient corrosion and stress margin to ensure a life time, without failure, not

less than life of the plant. 7000 complete cycles of operation shall be considered for

stress analysis purpose. Piping system shall not impose reactions on equipment

terminals exceeding permissible limits even under adverse operating conditions.

Personnel injury from discharge of hot fluids from drain, steam traps, vents, relief

valves, hot pipes or exposure to pipe vibration shall be guarded against.

⇒ Piping coming under the purview of Indian Boiler Regulations (IBR) shall be

designed in accordance with such regulations. The design criteria of piping coming

under the purview of IBR shall have to be approved by "Chief Inspector of Boilers"

Bihar, India prior to manufacture. All welding procedures, stress relieving

procedures, inspection / testing / certificates and all other records shall have to be

approved by Chief Inspector of Boilers in approved form.

⇒ Pipes shall be sized for minimum pressure drops and considering the velocity

limitation for various types of fluids as given in Table -08.4. Pipe thickness shall be

as per the pipe thickness schedules.

⇒ Pipes having nominal bore less than 15 mm, shall not be used. Design pressure of

steam and all other service pipelines shall be considered as 1.2 times the maximum

expected pressure. However it shall not be less than 4.0 kg/cm2 gauge for steam

services and 3.5 kg/cm2 gauge for other services. Design temperature for steam

services shall be as pr IBR and for other pipelines shall be 5 deg. above the maximum

sustained service temperature expected.

⇒ All the piping coming under the purview of IBR, shall be designed with the allowable

design stresses as per IBR. For all other piping, the allowable design stress shall not

be more than that specified in ANSI B 31.1 or BS:806 latest revision. Pipe thickness

of all pipeline shall be taken as per the pipe thickness schedules. The design and

stress analysis shall take into account the effect of internal/external pressures, thermal

expansion, self weight of piping, support reactions, shock due to relieving devices,

surge and water hammer, earth quake and wind effect, noise and vibrations, corrosion

and erosion etc. and any other effects dictated by recommended engineering

practices.

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⇒ Adequate flexibility shall be provided in the pipelines to keep stress and reactions in

the system arising due to thermal expansion or other effects within limits. Where the

piping terminates at an equipment or at the terminal point of a system, the reactions

and thermal movement imposed by piping on the equipment or the system concerned

shall be well within the limits specified.

⇒ The flexibility analysis of steam, condensate and hot service media pipelines shall be

furnished.

⇒ If cold springing of pipeline is used, care shall be taken in determining the location

and amount of cold spring gap. Cold spring gap shall be located at points where the

bending and torsional moments are minimum. Use of cold spring gaps less than 10

mm shall not be acceptable and cold spring gaps above 100 mm shall be avoided. All

outdoor piping exposed to sunlight carrying fluid at a temperature less than 80 deg.C

shall be designed considering thermal expansion corresponding to 80 deg.C and

empty pipe as one of the operating conditions although not necessarily the worst.

02.21.03 General Requirement

⇒ Unless otherwise specified, all piping shall have butt welded connections with

minimum of flanged joints for connection to vessels and equipment to facilitate

erection and maintenance, All high pressure steam valves and accessories shall have

welded connections. Standard fittings shall be used wherever practicable. Unless

otherwise specified, for all welded lines with pressure above 7 kg/cm2 and/or

temperature above 200 deg.C, branch connections with branch sizes upto 25 % of

welded mains shall be made with special forged steel welded fittings.

⇒ Bends for pipes other than general water pipelines shall have a radius of not less than

three times the nominal pipe dia unless otherwise specified.

⇒ In general pipes having size 50 mm and above, are to be jointed by butt welding and

40 mm & lower sizes by socket welding/screwed connection. Threaded joints shall

have to be seal welded except for galvanised pipes where teflon sealing tapes shall be

used. For galvanised pipeline, pipe joints which are to be made before galvanising

shall be of weldable type. Those joints which are to be made after galvanising shall be

either flanged or screwed type. As far as practicable, whole fabricated piping

assemblies shall be galvanised at a time in order to minimise the number of joints to

be made after galvanising. However, for instrument grade air line, GI pipes with

welded joints shall be used for sizes NB 25 mm and above; screwed joints for lower

sizes pipes upto NB 20.

⇒ All pipelines shall be provided with drain connections, generally at the lowest point

for removing accumulated condensate or water and line draining. The drain pipings

shall have drain pockets and isolation valves. Trap stations shall be provided,

wherever necessary.

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Lines shall be given proper slope towards the drain points. Drip legs on mains on line

dia 150 mm or over shall be at least 75 % of the main dia with a depth twice the dia

of the main or 600 mm minimum from the centre line of the main to the trap off-take

unless otherwise specified. Drip legs on mains smaller than dia 150 mm shall be full

dia of the line. All drip legs for fluids which may deposit undesirable liquid or solid

matter shall have full dia flanges for the bottom cover.

⇒ Steam traps shall be provided with integral or separate strainers, by-pass and isolation

valves. All high pressure drain piping shall have two isolation valves on either side of

it. All drains released into a sewer shall not exceed 60 deg.C. All the highest points in

a piping shall generally be provided with adequate venting arrangement with isolation

valves. High temperature vents shall be routed outside the building or at a safe height

of personnel protections. Silencers shall be provided at safety valves exhaust. Drain

line shall not be less than 25 mm. For main header size 100 mm & above, traps

minimum size shall be 25 mm.

⇒ Expansion joints shall not be used on steam lines. Sight flow indicators shall

preferably be of flapper type provided with illuminating arrangement. A safety valve

shall be provided at the down stream of every pressure reducing station.

⇒ All piping 50 mm in size and larger shall be fabricated in the manufacturer's shop.

Small piping materials shall be shipped separately in straight lengths and fabricated at

site. If any flow nozzle is required, it shall be fixed in a pipe piece in the shop.

02.21.04 Pipe supports, anchors, restraints

⇒ In general pipe, supports, restraints, braces or anchors shall be located at those points

in the building or outdoor where provision has been made for the loads imposed.

Loads at the supporting points or restraints shall be determined sufficiently early and

provision shall be made in the building or outdoor structures for pipe supports. The

tenderer shall locate, design, supply and erect all the supplementary steel structures to

properly secure and support all pipe hangers, supports, restraints, etc.

⇒ Provision shall be made for support of piping which may be disconnected during

maintenance work. All large pipes and all long pipes shall have at least two supports

each arranged in such a way that any length of piping or valve may be removed

without any additional supports being required.

⇒ Supports, guides and anchors shall be so designed that excessive heat is not

transmitted to the building structures. Supporting steel shall be of structural quality.

Perforated, strap, wire or chain shall not be used. Supporting components shall be

connected to supporting structure by welding, bolting or clamps. Bolt holes shall be

drilled and not gas cut. Structural steel work for supporting shall be designed on the

basis of maximum design stress of 1265 kg/cm2. Pipe attachment coming in direct

contact with pipes having surface temperature above 400 deg.C shall be made of alloy

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steel. Use of insulating materials like asbestos between pipe clamp and pipe surface to

meet the above temperature limitation shall not be permitted. The maximum spacing

between two consecutive supports shall be not more than as specified in Table - 08.5.

Pipe hangers and supports shall be capable of supporting the pipelines under all

conditions of operation. They shall allow expansion and contraction without over

stressing the piping system or overloading the terminal equipment due to variation in

supporting effort. Rigid supports or hangers shall be permitted only for pipes with

small movements. For hot lines, spring hangers shall be used. The maximum

permissible load variation on the terminals of sensitive equipment between hot and

cold conditions shall be limited to 6 %. Variability in load between hot and cold

conditions expressed as a percentage of the design load shall be taken as the criterion

for spring selection for spring hangers. Variable spring hangers shall be set at cold

conditions so that they take design load under operating condition after the designed

thermal expansion has taken place.

⇒ Spring shall be enclosed in suitable cages and the hangers shall be provided with

spring locking arrangement, external load and movement indicator and turn buckles

for load adjustment. All the rigid hangers shall be provided with turn buckles for

vertical length adjustments.

⇒ Hanger rods shall be subjected and designed for tensile loads. At locations of high

axial or lateral movement, suitable arrangement shall be provided to permit the swing.

The swing from vertical position shall be within 4 deg. Double nuts and locknuts

shall be used for hanger rods and bolts in all cases. Hangers shall be designed so that

they do not become disengaged by movement of supported pipe.

⇒ The supporting structures at each support point shall be designed for the highest of

the following loads to take into account the extra load during hydraulic testing.

o 1.25 times the maximum load under operating condition.

o 1.25 times the weight of pipeline full of water

o Weight of pipeline full of water (combined weight of pipe, insulation, valve

attachment etc. plus weight of water).

o 1.25 times the weight of pipeline ((combined weight of pipe, insulation,

operating medium and valve attachment)

o Weight of pipeline full of water as above plus any cold reaction as anticipated.

⇒ Where the piping system is subjected to shock loads such as thrust imposed by the

actuation of safety valves, hanger design shall include provision of shock absorbing

devices of approved design. Vibration control devices shall be part of piping system

design.

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⇒ Outdoor piping shall be designed, with due consideration, for expansion resulting

from exposure to sunlight and care shall be taken to prevent progressive movement of

long pipeline. Out door piping may be supported on shoes, saddles or steel sections.

Effect of support friction especially for large dia pipelines shall be considered and

friction forces minimised by suitable arrangement. Piping inside the trenches shall be

supported at intervals on steel sections and the arrangement shall permit easy

maintenance. Spacing of pipes in tunnels and trenches shall be as shown in table

08.10.

⇒ Walkway platform for outdoor over ground pipelines on stockades, if any, will be

provided for pipeline maintenance, including maintenance platform for gland

compensator, if any.

02.21.05 Valves and Specialties

⇒ All valves shall be of approved make and type. All valves shall be suitable for

service condition i.e. flow, pressure and temperature under which they are required to

operate, chemical characteristics & nature of operation. The valves for high and

medium steam services shall have butt welded/flanged ends unless otherwise

approved and the internal dia shall be same as that of the pipes to be joined.

⇒ All gate/sluice, globe and needle valves shall be fitted with outside screwed spindles

and bolted type glands and covers. Spindle glands shall be of the bridge type

construction and screwed glands will not be accepted. All high pressure valves having

nominal dia more than 150 mm, shall have integral steam bypass connected to the

valve body by means of welded joints.

⇒ All gate/sluice, globe and needle valves shall be provided with hand wheel and

position indicator. The face of each hand wheel shall be clearly marked with words

"open" and "shut" with arrows to indicate the direction of rotation to which each

refers. Arrangement limiting the travel of any valve in the "open" and "shut" position

shall be provided exterior to the valve body. All globe valves shall be designed to

prevent erosion of valve seats when the valves are operated partially opened. Valves

which cannot be operated from the floor or walkways, shall be provided with suitable

extension rods and linkages to facilitate operation from the floor or walkways. Chain

operation will not be accepted for steam valves. Stem shall preferably be arranged

vertically with gland at the top. In no circumstances, the gland be at the bottom.

Valves shall not be installed in the inverted position. The design of valves shall be

such that with back seat arrangement it will permit repacking of glands under

pressure. Where required, valve spindles shall be extended so that the hand wheel is

at a height of about 1.0 m above the level of the floor or platform from where the

valves are to be operated. Where required, they shall be provided with head stocks

and pedestals of rigid construction and where gears or bevel wheels are used, these

shall be of cast steel.

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⇒ Globe type valves shall have a permanent "arrow" inscription on its body to indicate

direction of flow.

⇒ Gate/globe valves on steam, air, condensate services shall be outside screw & yoke

type with rising spindle. Smaller size valve shall have rising hand wheel but larger

ones (NB 50 & above) only non rising hand wheel.

⇒ Non return valves on all pumps discharge and steam line shall be of an approved non-

slamming type. Draining arrangement shall be made on both sides of the horizontal

non-return valve where such a valve adjoins an isolating valve. Valve bodies shall be

provided with removable access cover to enable the internal parts to be examined

without removing the valves. Valves shall have a permanent "arrow" inscription on

its body to indicate direction of flow.

⇒ Non-return valves of sizes NB 250 and above shall have anti-slamming devices. Non-

return valves shall be lift check type for size upto Dn 50 mm and swing check type

for higher sizes.

⇒ Valves coming under the purview of IBR, shall meet its requirement.

⇒ Gate/sluice valves for low pressure service shall be outside screw rising spindle type.

For these valves, wherever necessary, chain operator shall be provided to operate the

valve from the floor or walkways. Larger size gate valves for low pressure

applications shall be provided with bypass and draining arrangement and valves with

dia more than 250 mm shall be provided with gear operator.

⇒ Valves in corrosive service shall be diaphragm or rubber lined type. Diaphragm shall

be of reinforced rubber and rubber lining of body shall have minimum thickness of 3

mm. Generally plug valves shall be used in compressed air line. Plug valves shall be

supplied with wrench operator. Valves shall be of taper plug type. Sampling valves

for dematerialized water shall be of cock type and stainless steel AISI 316. Indicator

for 'OPEN/ & 'CLOSE' position shall be provided on all plug valve.

⇒ For motor operated valve, a 415V, 3 phase, 50 Hz reversible speed motor shall be

furnished. Motor shall be capable of producing not less than 1.5 times the required

operator torque. Each operator shall be equipped with two adjustable limit and

torque switch for both open and closed posit-ion. The motor shall be of high torque

low starting current. Each operator shall be provided with auxiliary hand wheel for

manual operation. The hand wheel shall automatically disengage when the operator is

energized.

⇒ Manual operator shall be of worm and gear type, having permanently lubricated,

totally enclosed gearing with hand wheel diameter and gear ratio designed to meet the

required operating torque. The operator shall be designed to hold the disc in any

intermediate position between full open and full closed without creeping and

fluttering. Adjustable stop shall be built into the operator to prevent over travel in

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either direction. Operator shall be equipped with direct coupled position indicator and

suitable locking device.

⇒ Pressure reducing valves shall be perfectly stable, quiet and vibration less in

operation when reducing the pressure for any throughput up to maximum and shall be

suitable for continuous use at operating temperature. Valves shall be designed to

prevent erosion of the valve seats. Safety valves shall be the direct spring loaded type

and shall have a tight, positive and precision closing. All the safety valves shall be

provided with manual lifting lever. Safety valves used for compressible fluids shall be

of pop type. Safety valves shall be so constructed and adjusted to permit the fluid to

escape without increasing the pressure beyond 10 % above the set-blow off pressure.

Valve shall reset at a pressure not less than 2.5 % and more than 5 % of the set

pressure.

⇒ The seat and disc of safety valves shall be of suitable material to resist erosion. The

seat of valves shall be fastened to the body of valve in such a way that there is no

possibility of seat lifting.

⇒ Steam traps shall be impulse type, inverted bucket type, thermodynamic type or any

other proven design and shall be complete with integral or separate strainer. The

integral components of the traps including the strainer screen shall be of stainless

steel (AISI : 316) .

⇒ Valves on dry air line shall be non-lubricated / non-greased type. Graphited gland

packing shall not be used for it.

⇒ The compressed air hoses shall be as per IS:911, IS:446 or any other internationally

accepted standard. Strainer shall be of stainless steel AISI:316. Body material shall be

suitable for the service condition. Blowing arrangement shall be provided with

removable plug at the outlet.

⇒ All pipes, fittings, valves, gaskets, steam traps, flanges etc. shall be as per the

Annexure-1 to 7 for various services for design, manufacture, material, types, end

connections, testing etc.

02.21.06 Thermal Insulation

⇒ The tenderer shall furnish heat insulation for all necessary equipment and piping to

efficiently prevent abnormal heat loss from all exposed parts to limit surface

temperature within 60 deg.C. Resin bonded mineral wool/slag wool, fiber glass,

asbestos ropes and preformed pipe sections, mats/mattresses form of insulation

conforming to IS:8183/IS:9842/IS:7413 will be acceptable, however, the grades shall

be selected considering respective temperature. In case of using loose insulation,

proper care shall be taken at site to get recommended density. Packing density of the

insulation wool shall be 150 kg/m3. The various insulation thickness shall be taken as

recommended in Table 08.7.

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⇒ Insulated surface of ail equipment, piping, valves and fittings shall be covered with

aluminium sheet of 22 SWG (0.8 mm thick) held in place by self tapping screws of

nickel plated type. apart from the screw, joints shall be further sealed with a suitable

sealing compound. All fastening materials such as clips, wires for field weld to the

equipment, galvanised wire mesh, metal corner bead shall be provided. Where valves,

pipes fittings, flanges, etc. occur, a clear space between end of covering and flange

shall be left of sufficient length, to permit withdrawal of flange bolts without

interference. Ends of the covering at those joints shall be levelled from the outside

covering to the pipe and sealed.

Flanges, valves bonnet, end flanges and fittings shall be effectively insulated. Valve &

flange insulation covers shall be made in two halves so that these may be

removed/refitted readily without interfering with the adjacent covering. Protrusions

through the insulation which themselves do not require insulation such as pipe clamps,

supports, small piping, instrument take-offs, etc. shall be covered to the same thickness as

the adjacent insulation and be tightly sealed except at hanger rods. Ample provision shall

be made to prevent damage of insulation due to thermal movement of the pipe or

equipment. All the services to be insulated shall be cleaned of all foreign materials such

as scale, rust and paint by use of steel wire brushes and steel scrapers. Anti corrosion

painting (primer coat) shall be applied on hot surfaces before application of insulation